Patent Abstract:
A pinless inside door handle assembly has a housing, a latch handle and a lock lever that snap together and require no separate pivot pin. Interrelating projections and enclosed apertures are in pivotal engagement.

Full Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to automobile door handle assemblies, and, more particularly, the invention relates to a compact door handle assembly in which a door latch release handle and lock lever are contained in a single housing.  
       BACKGROUND OF THE INVENTION  
       [0002]     Vehicle door handle assemblies are known to include a door latch release handle connected by a cable to the door latch mechanism that is triggered to release the door by operation of the handle. Vehicle doors also are known to include a lock mechanism to secure the door in a closed. Manually operated lock mechanisms include an activator lever or button for engaging and disengaging the lock mechanism.  
         [0003]     Manually activated door handle mechanisms have taken a variety of different constructions. For safety reasons, smooth designs are preferred, without projecting components. Safety and functionality have driven designs toward smooth, sleek appearances in which both the latch handle and lock lever are inset in the door panel, often contained in a single housing or located adjacent each other in a portion of the door. Cables from each the latch handle and the lock lever interconnect the handle and lever to the respective mechanisms for releasing the door and for locking and unlocking the door. Moving the latch handle actuates the latch mechanism to unlatch the door. The latch handle returns to the non-actuating position when it is released. Lock mechanisms are known to operate with a lock lever that toggles between locked and unlocked positions.  
         [0004]     It is known to use a pin or pins through the latch handle and lock lever to secure the handle and lever in the housing. The handle and lever each can be rotated about the pin during operation and use of the mechanisms. The pin or pins are inserted through apertures in the housing and handles and must be secured therein. The use of a fastener or retainer such as a compression cap on the pin ends effectively retains the pin in position but renders the assembly of the mechanism both complicated and time consuming.  
         [0005]     U.S. Pat. No. 5,895,081 entitled “Inside Door Handle Assembly For Vehicles” proposes an assembly in which housing walls include projections and the latch handle and lock knob include through holes received on the projections. A wall of the knob defining one of the through holes is provided with a cutout portion so that a part of the wall around the hole is deformable. The cutout has a width less than the width of the projection received therein. Utilizing a cutout entrance into the aperture is not preferred in that the material is necessarily thin to allow adequate deflection, which can lead to fractures and failure. Deflection is localized in a small area, leading to possible material fatigue and failure. Further, the potential exists for the knob to become misaligned such that the projection partly re-enters the slot, potentially causing malfunction of the knob. Therefore, smooth, continuous apertures surrounding the projections are preferred.  
         [0006]     It is desirable to provide a pin-less inside door handle assembly that is easy to assembly and secure in final assembly.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention provides a snap-together assembly having no separate pivot pin, but instead interrelating projections and enclosed apertures in pivotal engagement.  
         [0008]     In one aspect thereof, the present invention provides a door handle assembly with a housing including a first outer wall defining a first aperture, a second outer wall defining a second aperture, and a partition wall between the outer walls. The partition wall has a projection extending toward the second outer wall. A latch handle has a handle projection received in one of the apertures of the first and second outer walls. The latch handle defines a latch handle aperture receiving the partitioned wall projection therein. A lock lever has a lock a lever projection received in the other of the apertures in the outer walls, and the lock lever defines a lock lever aperture receiving the projection of the partition wall. One of the latch handle and the lock lever spans the partition wall.  
         [0009]     In another aspect thereof, the present invention provides a vehicle door handle assembly with a housing having first and second outer walls and a partition wall. The housing has a first chamber defined between the first outer wall and the partition wall, and a second chamber between the second outer wall and the partition wall. The first outer wall has a first outer wall aperture, and the second outer wall has a second outer wall aperture. The partition wall has a projection extending into the second chamber. A latch handle is received substantially in the first chamber, and has an extension spanning the partition wall and a panel from the extension extending into the second chamber. The latch handle has a latch handle projection received in the first outer wall aperture and a latch handle aperture in the panel receiving the partition wall projection. A lock lever is received in the second chamber, and is disposed between the latch handle partition and the second outer wall. The lock lever has a lock lever aperture for receiving the partition wall projection and a lock lever projection received in the second outer wall aperture.  
         [0010]     In still another aspect thereof, the present invention provides a method for assembling a vehicle door handle assembly. A housing is provided with first and second outer walls defining first and second apertures, and a partition wall therebetween. A projection is provided on the partition wall directed toward the second outer wall. A latch handle is provided having an aperture therein and a projection therefrom. Assembly further includes aligning axially the projection of the latch handle with the aperture of the first outer wall and the aperture of the latch handle with the projection of the partition wall; causing relative lateral movement between the latch handle and the housing and causing the latch handle projection to be received in the first outer wall aperture and the partition wall projection in the latch handle aperture; providing a lock lever having a lock lever aperture and a lock lever projection. Assembly further includes aligning the lock lever aperture with the partition wall projection substantially parallel thereto but outwardly therefrom, and the lock lever projection with the second outer wall aperture substantially parallel thereto but outwardly therefrom; urging the lock lever between the partition wall and the second outer wall while deflecting the partition wall and the outer wall outwardly relative to each other; and engaging the lock lever projection in the second outer wall aperture and the lock lever aperture around the partition wall projection outwardly on the partition wall projection from the latch handle aperture.  
         [0011]     An advantage of the present invention is providing an inside door handle assembly that is compact.  
         [0012]     Another advantage of the present invention is providing an inside door handle assembly for vehicles, which is stable in operation, yet easy to assembly.  
         [0013]     Still another advantage of the present invention is providing an inside door handle assembly with few independent parts, consisting of only a few monolithic structures.  
         [0014]     Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a perspective view of a pin-less inside door handle assembly in accordance with the present invention;  
         [0016]      FIG. 2  is an exploded perspective view of the door handle assembly shown in  FIG. 1 ;  
         [0017]      FIG. 3  is a an exploded perspective view of the door handle assembly shown in  FIGS. 1 and 2 , but shown from a different side than shown in  FIG. 2 ; and  
         [0018]      FIG. 4  is a cross-sectional view of the pin-less inside door handle assembly, taken along line  4 - 4  of  FIG. 1 . 
     
    
       [0019]     Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use herein of “including”, “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items and equivalents thereof.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0020]     Referring now more specifically to the drawings and to  FIG. 1  in particular, a door handle assembly  10  in accordance with the present invention is shown. Door handle assembly  10  includes a housing  12  adapted for installation and attachment in a vehicle door panel, armrest or the like. A latch handle  14  and lock lever  16  are operatively disposed in housing  12 . A latch cable  18  is connected to latch handle  14  at one end, and at the opposite end to a latch/release mechanism (not shown) of the vehicle door. A lock cable  20  is connected at one end to lock lever  16  and at an opposite end to a lock mechanism (not shown) of the vehicle door. As shown in  FIG. 2 , door handle assembly  10  further includes a biasing spring  22  and a resilient bumper  24  operatively associated with latch handle  14  in housing  12 .  
         [0021]     The specific configuration of housing  12 , latch handle  14  and lock lever  16  vary for installation in a variety of different vehicle doors. Thus, the specific shape, size and the like of each shown in the drawings is for purposes of illustration and should not be considered as limiting on the scope of the present invention.  
         [0022]     Housing  12  is a monolithic structure of plastic or the like, and includes a first outer wall  30  a second outer wall  32  and a partition wall  34  disposed between first and second outer walls  30  and  32 . End panels  36  and  38  interconnect first and second outer walls  30 ,  32  and partition wall  34 . Various mounting structures  40  are provided, by which housing  12  is secured in a vehicle door panel, armrest or the like.  
         [0023]     First and second outer walls  30 ,  32  and partition wall  34  are spaced from each other to define first and second chambers  42  and  44 , respectively. First outer wall  30  defines a first outer wall aperture  46 . Second outer wall  32  defines a second outer wall aperture  48 . Apertures  46  and  48  have openings thereto in first and second chambers  42  and  44 , respectively. Partition wall  34  defines a boss or projection  50  extending therefrom into second chamber  44 , generally directed toward second outer wall  32 . In an advantageous configuration of the present invention, first outer wall aperture  46 , second outer wall aperture  48  and partition wall projection  50  are arranged in housing  12  in substantially axial alignment.  
         [0024]     End panel  36  defines first and second cable slots  52  and  54  for receiving and holding latch cable  18  and lock cable  20 , respectively. Grommet-like fittings  56  and  58  are providing on cables  18  and  20 , respectively, by which cables  18  and  20  are secured in cable slots  52  and  54 .  
         [0025]     First chamber  42  includes a cross member  60  defining a channel  62  therein for receiving a shaped anchor portion  64  of bumper  24 .  
         [0026]     Housing  12  has an exposed or outer end  66  disposed generally at the surface of the door panel or armrest in which it is installed for use, and a non exposed or inner end  68  generally within the door panel, armrest or the like. For ease and clarity of description herein, reference will be made to the outer and/or inner ends, sides or directions of various components. Such descriptions should be understood to mean the portion, surface, direction, etc. that is more closely positioned to outer end  66  or inner end  68 , and not necessarily positioned at the extreme outer or inner end.  
         [0027]     Latch handle  14  and lock lever  16  are disposed in first and second chambers  42  and  44 , respectively, generally at outer end  66  and extending toward inner end  68 . Cables  18  and  20  connect to latch handle  14  and lock lever  16  within chambers  42  and  44 , respectively. Channel  62  of cross member  60  is open at the outer end and closed at the inner end (not shown) thereof. Anchor portion  64  of bumper  24  can be inserted into channel  62  from the outer end thereof, and secured therein by resting against the closed inner end of channel  62 .  
         [0028]     First outer wall aperture wall  46 , second outer wall aperture  48  and partition wall projection  50  are in substantially axial alignment near outer end  66  of housing  12 . Latch handle  14  and lock lever  14  are configured for attachment to housing  12  via first outer wall aperture  46 , second outer wall  48  and partition wall projection  50 , as will be described more fully herein after. Latch handle  14  and lock lever  16  are rotatable through at least limited arcs within housing  12 .  
         [0029]     Latch handle  14  is a substantially monolithic structure of molded plastic or the like, and includes a hand grasp  80  having an anchor end  82  and a distal end  84 . An inner arm  86  of latch handle  14  is integral with hand grasp  80  and forms a generally right angle with hand grasp  80  such that arm  86  extends into first chamber  42  with hand grasp  80  extending substantially along outer end  66  of first chamber  42 . At anchor end  82 , latch handle  14  defines a latch handle aperture  88  configured to slide over partition wall projection  50 . Latch handle  14  further defines a latch handle projection  90  directed outwardly therefrom, and configured to be received in first outer wall aperture  46 . Since partition wall projection  50  is directed toward second outer wall  32  and extends into second chamber  44 , latch handle  14  includes an extension  92  that spans partition wall  34 , and a inwardly depending panel  94  that extends into second chamber  44 . Latch handle aperture  88  is provided in panel  94 .  
         [0030]     At a lower end thereof, inner arm  86  defines a hole  96  and a slot  98  for receiving and securing latch cable  18 , and specifically a ball  100  at one end of latch cable  18 .  
         [0031]     Lock lever  16  is a substantially monolithic structure of molded plastic or the like, configured to be received in second chamber  44 . Lock lever  16  includes an outer face  110  having a slight tail  112  to facilitate lift. Lock lever  16  is a substantially block-like body, not necessarily solid or smooth, and defines a lock lever aperture  114  on one side thereof and a lock lever projection  116  on the opposite side thereof. Lock lever  16  includes a connector portion  118  extending into second chamber  44 . Lock lever aperture  114  and lock lever  116  are somewhat centrally located at the sides of lock lever  16  such that, when connected in housing  12 , lock lever  16  can be toggled between first and second positions for locking and unlocking the door. Lock lever aperture  114  is configured for receiving partition wall projection  50  therein, and lock lever projection  116  is configured for being received in second outer wall aperture  48 . Connector portion  118  defines a hole  120  for receiving a substantially right angle anchor  122  at one end of lock cable  20 .  
         [0032]     During assembly, bumper  24  is attached to cross member  60  of housing  12  by sliding anchor portion  64  into channel  62 . Inner arm  86  of latch handle  14  is inserted into first chamber  42  of housing  12 , with latch handle  14  being offset toward partition wall  34 . Extension  92  spans partition wall  34  such that panel  94  depends from extension  92  into second chamber  44 . Latch handle aperture  88  is aligned axially with partition wall projection  50 , and latch handle projection  90  is aligned axially with first outer wall aperture  46 . Relative lateral movement is created between housing  12  and latch handle  14  such that latch handle projection  90  is inserted into first outer wall aperture  46 , and partition wall projection  50  is inserted into latch handle aperture  88 .  
         [0033]     Lock lever  16  is moved into position at outer end  66  of housing  12 , with lock lever aperture  114  positioned substantially parallel to and outwardly of partition wall projection  50 , and lock lever projection  116  positioned substantially parallel to and outwardly of second outer wall aperture  48 . Lock lever  16  is urged into chamber  44  such that second outer wall  32  and partition wall  34  are displaced slightly away from each other, allowing lock lever  16  to be inserted. During insertion, lock lever aperture  114  and lock lever projection  116  become axially aligned with partition wall projection  50  and second outer wall aperture  48 , respectively. Partition wall  34  and second outer wall  32  spring back to non-deflected positions such that partition wall projection  50  is received in lock lever aperture  114  and lock lever projection  116  is received in second outer wall aperture  48 . Panel  94  is thereby disposed on partition wall projection  50  between partition wall  34  and lock lever  16 , and the entire assembly of housing  12 , latch handle  14  and lock lever  16  is thereby secured.  
         [0034]     To promote relative deflection between partition wall  34  and second outer wall  32  during a fluid operation to insert lock lever  16  into second chamber  34 , second outer wall  32  is provided with an inwardly angled, ramp-like surface  130  extending from an outer edge  132  of second outer wall  32  to an outer portion of second outer wall aperture  48 . An inner portion  134  of latch handle projection  90  is angled relative to the insertion direction of lock lever  16 , for sliding along ramp-like surface  130 . Connector portion  118  extending into second chamber  44  is provided with an elongated ramp-like surface  136  leading to latch handle aperture  88 . Thus, lock lever  16  can be inserted partly into second chamber  44  without relative deflection between second outer wall  32  and partition wall  34 . Ramp-like and angled surfaces  130 ,  134  and  136  facilitate insertion of lock lever  16  into second chamber  34  and relative deflection outwardly between partition wall  34  and second outer wall  32 .  
         [0035]     With latch handle  14  and lock lever  16  secured within housing  12 , spring  22  is inserted into first chamber  42  from inner end  68  thereof. Spring  22  includes legs  140  and  142  secured against housing  12  and latch handle  14  so as to bias latch handle  14  toward a position in which the vehicle door latch mechanism (not shown) is secured.  
         [0036]     Latch handle  14  and lock lever  16  can pivot about the respective connections thereof to housing  12 . Substantially smooth interfaces are provided between apertures  46 ,  48 ,  88  and  114  and projections  50 ,  90  and  116  received therein. Apertures  46 ,  48 ,  88  and  114  are enclosed at perimeters thereof by first outer wall  30 , second outer wall  32  latch handle  14  and lock lever  16 , respectively, to fully encircle the projections held therein. Smooth, reliable operation of latch handle  14  and lock lever  16  is promoted.  
         [0037]     Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.  
         [0038]     Various features of the invention are set forth in the following claims.

Technology Classification (CPC): 8