Patent Publication Number: US-10781617-B2

Title: Vehicular door handle assembly and method for assembling the same

Description:
FIELD 
     The present disclosure relates generally to vehicular door handle assemblies. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
     Vehicular door handle assemblies typically comprise two sub-components, i.e. a door grip assembly and a chassis assembly. The chassis assembly is secured onto the internal side of a metal sheet which forms the vehicular door and the door grip assembly is connected to the chassis assembly through a first forward passageway and a second rearward passageway provided in the vehicular door. While the chassis assembly is positioned on the internal side of the door panel, the handle assembly is positioned on the external side of the door panel; the assembling operations of door handle thus require to secure an external door grip on an internal chassis assembly, bearing in mind that, once assembled, the door grip is configured to be movable in a position where the door handle releases an appropriate door latching mechanism. To this end, the door grip is usually linked with a bellcrank which in turn is suitably connected to the door latching mechanism. 
     Prior art door handle assemblies prove not to be entirely satisfactory as they, and especially their chassis assembly sub-component, tend to be complex and expensive to make. 
     SUMMARY 
     The present disclosure provides a vehicular door handle assembly for opening a vehicle door comprising: 
     a door grip having a forward end and a rearward end, movable from a resting position where the vehicle door is latched to an actuated position where the vehicle door is unlatched; 
     a chassis assembly having a forward end and a rearward end, the chassis assembly supporting, at its rearward end; 
     a bell crank rotatably connected to the chassis and connected to the door grip, configured to pivot between a resting position and an actuated position when the door handle is actuated; and 
     a moveable retaining element configured to retain the bellcrank in a serviceable position where the door grip can be connected to the bellcrank and to release the bellcrank to a functional position where the bellcrank can rotate between the resting position and the actuated position. 
     In one form, the bellcrank rotates with regards to the chassis within an angular stroke defined by: 
     a serviceable position wherein the retaining element maintains the bellcrank in a position where the door grip is connectable or disconnectable from the bell crank; 
     a resting position wherein the bellcrank maintains the door grip against the vehicle door; and 
     an actuated position wherein the retaining element maintains the bell crank in a position wherein the bell crank actuates a latch mechanism and wherein the bellcrank remains engaged with the door grip. 
     In one form, the present disclosure provides a driving feature operable from the chassis rearward end configured to move the retaining element relative to the chassis assembly from the serviceable position to the resting position. 
     In one variation, the retaining element comprises a sliding element having a sliding part and at least one arm configured to cooperate with the bellcrank. 
     In an another variation, the at least one arm includes a hook and the bellcrank includes a shoulder where the hook seats. 
     In still another variation, the sliding element includes at least one rotation stop where the bellcrank abuts in the actuated position, wherein the bell crank actuates a latch mechanism and wherein the bellcrank remains engaged with the door grip. 
     In yet another variation, the chassis includes a central opening and the bellcrank includes a locking clip, which is substantially flush with the central opening in a serviceable position. 
     In a further variation, the bellcrank angular stroke is defined by the hook provided at the end of the at least one arm and by at least one rotation stop provided at the sliding member front end. 
     The present disclosure further provides a method of installing a vehicle door assembly on a vehicular door panel having an external side and an internal side and at least a front passageway and a second passageway, the method comprising the steps of: 
     providing a chassis assembly having a forward end and a rearward end, said forward end having connecting features and said second end having a rotatable bellcrank maintained in a serviceable position by a retaining element; 
     securing the chassis assembly on the internal side of the door panel; 
     providing a door grip movable to an actuated position to open a vehicle door, having a forward end and a rearward end, said forward end having a connection feature to connect with chassis front end connecting features, said rearward end having a plunger; 
     mounting the handle grip on the chassis forward end; 
     connecting the plunger on the bellcrank; and 
     moving the retaining element to a position where the bellcrank can rotate between a resting position and an actuated position. 
     Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which: 
         FIG. 1  is an exploded perspective view of a door handle assembly according to one form of the present disclosure; 
         FIG. 2  is an exploded perspective view of a door grip of the door handle assembly of  FIG. 1 ; 
         FIGS. 3 and 4  illustrate an internal view of two forms of a chassis assembly of  FIG. 1 ; 
         FIG. 5  illustrates an external view of a chassis secured on a door panel according to the present disclosure; 
         FIGS. 6 and 7  illustrate in perspective a chassis assembly and a door grip assembly according to the present disclosure; 
         FIGS. 8 and 9  illustrate a door handle assembly rearward pivot linkage where the door panel and other components have been removed according to the present disclosure; 
         FIG. 10  illustrates an external view of a door handle assembly in a resting position according to the present disclosure; 
         FIG. 11  illustrates an internal view of a door handle assembly in a resting position according to the present disclosure; 
         FIGS. 12 and 13  illustrate an internal view of a door panel assembly fitted on a door panel in an actuated position according to the present disclosure; and 
         FIGS. 14 and 15  illustrate alternative forms of a door grip according to the present disclosure. 
     
    
    
     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
     The present disclosure provides a door handle assembly and a method for installing the door handle assembly on a vehicle door. 
     It should be understood that the door handle assembly as described herein is characterized with respect to a forward, rearward, upper, and lower orientation, wherein forward is toward a front end of the vehicle, rearward is toward a rear end of the vehicle, external is away from the center of the vehicle and internal is closer to the center of the vehicle. This orientation is for exemplary purposes only and is not meant to limit the present disclosure in any manner. It will be apparent to one of ordinary skill in the vehicular handle art that the door handle assembly can be positioned on a vehicular door in any suitable fashion. 
     Referring now to  FIGS. 1 to 15 , the present disclosure is described in relation to exemplary forms thereof. 
     As shown, the vehicular door handle assembly of the present disclosure includes two subcomponents namely a chassis  2  and a door grip  3 . 
     The chassis  2  can be a plastic component which can be made by injection molding but other suitable materials are contemplated. The chassis  2  has an external face which is intended to face the internal face of an exterior vehicle door panel which can be made of metal or of any other suitable material and has an internal face opposite the external face. 
     As can be seen in  FIG. 3 , the chassis  2  includes a peripheral ridge  4  which makes provision for the chassis rigidity. 
     In the illustrated form of the present disclosure, the peripheral ridge  4  is comprised of two walls  5  and  6  linked by a series of ribs  7 . 
     In the illustrated variation of the present disclosure, the chassis  2  has an elongated shape and has a longitudinal axis A. 
     At its forward end, the chassis  2  is provided with a first opening  9 . The first opening  9  has a generally rectangular shape. The first opening  9  can be equipped with a rib structure  10  that contacts the internal face of a door panel when the chassis  2  is assembled to a door structure. Two holes  12  are provided in the wall which surrounds the front opening  9 ; a pivot pin  14  is inserted in the holes  12 . 
     In the illustrated form of the present disclosure, a rotatable arm  15  is mounted within the front opening  9  of the chassis  2 . To this end, the arm  15  has a central curved section  16  and a fork having two plain bearings  18  wherein the pivot pin  14  is inserted. The arm  15  is thus sturdily connected to the chassis  2 , as the pivot linkage which connects the arm  15  to the chassis  2  can extend over a significant transversal dimension. At its free end, the arm  15  can include a series of radial lugs  19 . 
     Next to the first opening  9 , the chassis  2  includes a central wall  21  that extends transversally within the peripheral ridge  4 . 
     At its second end, the chassis  2  includes a support section  22  which extends within the peripheral ridge  4  at the rearward end of the chassis  2 . 
     As it can be seen on the  FIGS. 1, 6, 7 and 10 , the transversal wall  21  and the support section  22  are spaced apart. In other words, the chassis  2  is provided with a central opening  24  which is defined between the transversal wall  21  and the support section  22 . 
     In the illustrated example of the present disclosure of  FIGS. 1 and 3 , the support section  22  can optionally be provided with a funnel  25  which extends from the internal face of the chassis  2 . The funnel  25  is configured to accommodate a plug  26 . The plug  26  can include a locking cylinder or any suitable mechanism for locking and unlocking the vehicle door with a key.  FIG. 4  shows one form where the support section is devoid of a funnel and thus cannot receive a plug. 
     The internal face of the chassis  2  is also equipped with a lug  27  provided with a hole suitable to receive a pivot pin  28 . An inertia lock  30  is mounted on the pivot pin  28  and is configured to inhibit the vehicle door from opening in the case of a deceleration force caused by an impact with the vehicle. 
     In one form, a bellcrank  31  is also rotatably mounted on the chassis  2 . To this end, the chassis  2  is provided with two holes  32  which are formed in the peripheral ridge  4 . A pivot pin  33  is inserted in the holes  32 ; the bellcrank  31  which includes a plain bearing  35  is engaged on the pivot pin  33  and thus the bellcrank  31  can rotate about the pivot pin  33 . The bellcrank  31  is biased by a torsion coil spring  34  toward a resting position that is to say a position where the door is latched by suitable means onto the vehicle body. As can be seen in  FIG. 3 , for example, the bellcrank  31  includes a shoulder  29 ; in the illustrated form, the shoulder  29  protrudes from the bearing  35 . 
     The bellcrank  31  is also equipped with a fork which has two locking clips  36 , each locking clip  36  includes two curved arms. The central opening  24  is sized and shaped to accommodate the bellcrank  31  and to allow rotation of the bellcrank  31  between a resting position of the bellcrank  31  wherein a vehicle door locked position and an actuated position of the bellcrank  31  wherein a vehicle door actuated position. To this end, the vehicle door is suitably equipped with appropriate features (not illustrated) to latch and actuate the vehicle door upon an action by a user on the handle grip. 
     The chassis  2  further includes a sliding member  37 . The sliding member  37  can move between a first rearward position and a second frontward position. The sliding member  37  can thus occupy (i) a first serviceable position where the sliding member  37  maintains the bellcrank  31  against the spring  34  in position where the locking clips  36  are substantially flush with the central opening and (ii) a second functional position where the sliding member  37  releases the rotation of the bellcrank  31 ; in the said second position of the sliding member  37 , the bellcrank  31  can rotate between its resting position and its actuated position. 
     As it will become apparent later, the serviceable position is a transitional position conveniently used during shipping, assembling and servicing of the chassis assembly. When assembled, the door handle assembly can be in a resting position wherein the door grip  3  is maintained against a door panel  70  and an actuated position wherein the door grip  3  is pulled by a user to open the vehicle door. 
     The sliding member  37  is provided with a sliding part  38  and an arm  40 . As can be seen in the Figures, the sliding part  38  has a general U-shape and includes an opening  44 . The opening  44  is defined between two longitudinal beams  45 . The sliding part  38  is suitably equipped with guiding tabs  39  which make it possible to guide the sliding member  37  in its move with regards to the chassis  2 . For this purpose, the chassis  2  is also equipped with a series of guiding lugs  41  where the guiding tabs  39  and the sliding part side edges are guided. The sliding member  37  is also provided with two rotation stops  43  which are located at the end of each longitudinal beam  44 . The arm  40  has a C-shape or gooseneck shape which goes around the bellcrank  31  and the end of which is fitted with a hook  42 . 
     In the illustrated form, the sliding member  37  is slidingly moveable relative to the chassis by a screw  46 . The sliding member  37  is provided with a tower structure  49  wherein a square nut  39  is secured by press fit. The screw  46  is engaged in the nut  39  while the screw head remains within a cage  58 . 
       FIGS. 3 and 4  show the chassis  2  in a so called serviceable position where the sliding member  37  is in its extreme rearward position. In the said serviceable position, the hook  42  is in contact with the bellcrank shoulder  29  and maintains the bellcrank  31  against the spring  34 . The sliding member  37  maintains the bellcrank  31  in the serviceable position where the locking clips  36  protrude from the central opening  24 .  FIG. 6 , for example, shows the chassis in its serviceable position with the locking clips  36  slightly protruding from the central opening  24 . 
     Referring now to  FIG. 2 , in one exemplary form, the door grip  3  can comprise a frame  50  which supports a handle shell  51 . The frame  50  supports at its rearward end a rotatable plunger  52  and is further provided, at its forward end, with a connecting feature configured to engage the rotatable arm  15  in a rigid manner. 
     The frame  50  has a general elongated and arcuate shape which makes it possible to accommodate a user&#39;s hand. 
     The handle shell  51  is positioned over the frame  50  and is suitably secured thereto by a series of tabs or similar suitable connectors which secure the hand shell  51  on the frame  50 . 
     Referring, for example, to  FIGS. 2 and 6 , the plunger  52  can include a central part  53  and four pins  54  positioned at both ends of the central part. Thus, the plunger  52  is connected to the frame  50  via a pivot linkage. The frame  50  is suitably provided with two holes  56  where two pins  54  of the plunger  52  can seat and rotate.  FIG. 8  shows the engagement of plunger pins  54  in the holes  56  provided in the frame  50  and the plunger  52  rotation authorized by the pivot linkage between the plunger  52  and the frame  50 . 
     At its forward end, the frame  50  includes means for connection with the rotatable arm  15 . In the illustrated example, the frame  50  includes an opening  60  which has a series of radial grooves  61  alternating with a series of radial retaining lips  62  which are sized and spaced to accommodate the radial tabs  19 . The radial grooves  61  and retaining lips  62  are spaced and oriented in manner such that when the frame  50  is placed in a position parallel to the frame A axis, the radial tabs  19  are locked by the retaining lips  62 . 
     Adjacent to the means for connection with the rotatable arm  15 , the frame  50  can include a passageway  63 . This passageway  63  can be optionally used for wires connecting an electronic module located in the door handle. 
     In other forms illustrated in  FIGS. 14 and 15 , the door grip  3  can include a plunger  52  rigidly attached to the frame  50  and/or can include a forward pivot arm  55  attached to the frame  50  bearing in mind that, in such case, the chassis is provided with suitable connecting features. 
     The operation of assembling the door handle assembly  1  of the present disclosure includes a first stage where the chassis  2  is secured on the internal face of the metal sheet which forms the vehicle door, by any suitable attachment means such as a rivet or screw, among others. 
     The door panel  70  which can be seen on  FIG. 5  is provided with an embossed area comprised of a central curved part  71  configured to accommodate the hand of a user, of a forward embossed section  72  and of a rearward embossed section  73 . In the illustrated form, the forward embossed section  72  is provided with a passageway  75  which has a substantially rectangular shape and the rearward embossed section  73  is provided with a passageway  76  proximate to the central curved part which has a rectangular slot shape and a distal passageway  78  which has a substantially round shape. 
     During this assembling stage, the chassis  2  is secured in the internal side of the door panel  70 . 
     The chassis  2  is its serviceable position that is to say in a position wherein the sliding member  37  maintains the bellcrank  31  as the hook  42  is in contact with the bellcrank shoulder  29  and maintains the bellcrank  31  against the spring  34 . 
     In a second stage shown in  FIGS. 8 to 10 , the forward end of the door grip  3  is attached to the forward end of the chassis  2 . 
     In the form illustrated of  FIGS. 1 to 7 , the door grip  3  is connected to the free end of the arm  15 . To this end, the arm  15  is fully rotated and protrudes above the surface of the metal sheet. 
     The door grip  3  is approached to the door panel embossed area and the attachment part of the chassis  2  is engaged on the arm free end. More precisely, in the illustrated form, the arm radial lugs  19  engage into the corresponding radial grooves  62 . By rotating the door grip  3  towards a position where the door grip is substantially superimposed with the chassis  2  longitudinal axis A, the radial lugs  19  eventually are superimposed on the retaining lips  62 . The attachment part can also suitably include a ramp to form a locking wedge. 
     Then, the door grip  3  rotates about the forward pivot linkage and connects the plunger  52  with the bellcrank  31 . To achieve this, the door grip  3  is rotated towards the embossed area, thereby bringing the plunger  52  into engagement with the bellcrank  31  as shown in  FIGS. 7 to 9 . By pushing the door grip  3 , the pins  54  provided at the end of the plunger  52  engage into the bellcrank  31  locking clips, thereby creating a rearward linkage of the door handle and the chassis  2 . 
     In the case of a door grip  3  as shown on  FIG. 15 , the forward pivot arm  55  is connected to suitable features provided in the chassis  2  forward end. 
     The next stage makes provision for the rear end linkage. The free end of the plunger  52  engages the locking clips  36 . As shown on  FIG. 6 , the plunger pins  54  can be provided with a flat portion  59  which allows introduction of the plunger pins  54  in the locking clips  36 . 
       FIGS. 8 and 9  show the plungers pins  54  engaged in the locking clips  36 . 
     To secure the rearward linkage between the door grip  3  with the chassis  2 , that is to say the linkage between the plunger  52  and the bellcrank  31 , the sliding member  37  is moved toward a forward position by rotation of the screw  46 . 
     By moving forward, the sliding member  37  releases the bellcrank  31  which in turn rotates about the pivot pin  33  and thus locks the plunger pins  54  in the locking clip  36 . In its forward position, the sliding member  37  is locked by the engagement of the guiding tabs  39  of the sliding member  37  in the guiding lugs  41  provided in the chassis  2 . 
     It can be noted that simultaneously, the sliding member  37  locks the plug  26 , should the door handle assembly include a plug  26 . 
       FIGS. 10 and 11  show the door handle assembly in a functional configuration and more precisely in its resting position, that is to say a position where the door is latched. 
     A user intended to open the vehicle door will pull the door grip  3 . By doing so, the plunger  52  triggers the bellcrank  31  rotation which releases the latch mechanism. 
     The bellcrank  31  angular stroke is set (i) at one end corresponding to the door handle assembly resting position (see  FIG. 11 ), by the handle grip  3  resting on the external face of the door panel  70 ; and (ii) at a second end corresponding to the door handle assembly actuated position (see  FIGS. 12 and 13 ) by the bellcrank  31  coming in abutment with the rotation stops  43 . 
     In the door handle assembly resting position, the hook  42  stays clear of the shoulder  29 , thus providing that the handle grip  3  is fully biased against the door panel  70 .  FIG. 11  shows the gap the between the hook  42  and the shoulder  29 . 
     In the door handle assembly actuated position that is to say when a user intends to open the vehicle door, the rotation stops  43  provided on the sliding member  37  provides that the bellcrank  31  does not over rotate to a position corresponding to the serviceable position where the bellcrank would disconnect from the plunger  52 . 
     It is also understood that the vehicular door handle assembly is easily reversible. In other words, by driving the sliding member  37  to its rearward position, this being done by operating the screw  46 , the handle grip  3  can be disconnected from the chassis  2 . The bellcrank  31  moves to its serviceable position where the locking clip  36  are flush with the passageway  76  allowing the plunger  52  to disengage from the bellcrank  31 . The door grip  3  can then be disengaged from the forward linkage. This proves to be advantageous, for example, when maintenance is required. 
     The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.