Abstract:
A door handle system may be used in many applications, including the automotive industry and specifically on the inside of an automobile door. Embodiments of the invention include a retainer in the door handle assembly to allow installation in blind areas, where the axle is only visible from the back and the handle only visible from the front. The retainer aligns with a groove in the axle and prevents the axle from backing out of the assembly. Embodiments of the invention ensure a tight fit between the handle and axle preventing the assembly from becoming inoperable if components become loose.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This Non-Provisional Application claims benefit to U.S. Provisional Application Ser. No. 60/808,079 filed May 24, 2006. 
     
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to door handle systems, and more particularly, to automobile inside door handle systems. 
       BACKGROUND OF THE INVENTION 
       [0003]    It is known that door handles are used in many applications, and are regularly used in the automobile industry. Specifically, door handle systems are used on the inside of automobile doors to facilitate opening of the door by passengers of the vehicle. 
         [0004]    Known door handle systems may be assembled in several different ways. Some automotive programs require that a door handle assembly contain a die cast handle and a die cast axle which must attach to each other as well as the handle and a bezel. The die cast parts, which are press fit together, require a secondary attachment to be used for safety. If the press fit were to come loose over time, the assembly could potentially fall apart. If the assembly falls apart, the release handle will no longer function properly. 
         [0005]    Other door handle systems use ramps or “C clips” which contact the bezel to prevent the axle from backing out of position and losing contact with the handle. A problem with these systems is that they may not maintain the proper fit between the axle and handle. The assembly will still function if the axle backs out of position, but the handle will feel loose and sloppy, which is undesirable. Also, component parts of these systems may cause interference with the bezel during normal operation, resulting in an undesirable feel of the handle. 
         [0006]    Another assembly option for door handle systems is to attach a retaining clip between the axle and handle after assembly. However, with this assembly, access to the area between the axle and handle is not always possible because of the bezel or bracket design. In some instances, only the axle is visible from the back and only the handle is visible from the front. 
         [0007]    The present invention is directed at overcoming these and other known drawbacks with existing door handle systems. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention is directed to door handle systems that may be used in many applications, including within the automotive industry. The invention provides a door handle system with a retainer attached to an axle that acts as a safety feature to prevent the axle from backing out of the assembly. The invention minimizes interference between assembly parts and with the bezel during operation, and further maintains a firm feel of the handle during operation. The invention may be installed in a blind area, where the axle is visible only from the back of the assembly and the handle is only visible from the front of the assembly. A further feature of the invention is that the retainer may not be removed after the components are assembled. The components of the assembly which are visible remain flush with the handle, providing an aesthetic look and feel for the user. 
         [0009]    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 
         [0010]      FIG. 1  is an isometric view of an assembled embodiment of an exemplary door handle system. 
           [0011]      FIG. 2  is an exploded isometric view of parts of an unassembled door handle system. 
           [0012]      FIGS. 3   a  and  3   b  are isometric views of a handle showing the handle slot and assembly of an exemplary retainer into the handle slot. 
           [0013]      FIGS. 4   a  and  4   b  are top and bottom views, respectively, of an exemplary retainer. 
           [0014]      FIG. 5  is an isometric view of an exemplary axle. 
           [0015]      FIG. 6  is a bottom view of a retainer and an isometric view of an axle prior to assembly. 
           [0016]      FIG. 7  is an isometric view of an axle engaged with a retainer. 
           [0017]      FIG. 8  is an isometric view of an axle, retainer, and handle assembled together. 
       
    
    
       [0018]    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 arrangement 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 to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “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 EMBODIMENTS 
       [0019]    The present invention may be embodied in many forms. One exemplary embodiment, depicted in  FIGS. 1 and 2 , is a door handle system  5  that may be used on the inside of an automobile door. The door handle system  5  provides a security feature by preventing the door handle  30  from becoming inoperable if press fit components separate. Components of the door handle system  5  include an axle  10 , a handle  30 , a bezel  40 , and a retainer  50 , which is shown in  FIGS. 3-4 . As described in more detail below, with the door handle system  5  of the invention, the axle  10  may be installed through the handle  30 , bezel  40  and retainer  50 . The retainer  50 , which is installed to the handle  30 , has an opening that is smaller than the diameter of the axle; however, a slot in the retainer allows the retainer  50  to spread so the axle  10  may pass through the opening. Chamfered surfaces on the installation side of both the axle  10  and retainer  50  allow the axle  10  to pass through the retainer  50 , while squared-off surfaces on the opposing sides of the axle and retainer prevent the axle  10  from backing out of the retainer  50  and consequently prevent the axle  10  from backing out of the handle  30 . With the embodiments of the invention, the door handle assembly  5  may be prevented from becoming inoperable in the event the press fit between the axle and handle becomes loose. 
         [0020]    Referring to  FIG. 2 , the bezel  40  may be configured to be a fixture to support other components of the door handle system  5 . The bezel  40  is also configured to be attached, for example, to the inside of a door frame. The bezel  40  defines an opening  41  configured to engage with the handle  30 , and defines an opening  42  to engage with the axle  10 . The bezel  40  may be made of any suitable material, such as nylon or acrylonitrile butadiene styrene. Similarly, the retainer  50  may be made of the same material as the bezel  40 . 
         [0021]    As illustrated in  FIGS. 2 ,  3   a , and  3   b , the handle  30  comprises a first handle end  32  and a second handle end  33 . The first handle end  32  is a free end that provides an area for a user to operate the handle  30 . As illustrated in  FIGS. 3   a  and  3   b , a surface of the second handle end  33  defines a complimentary shape to that of the bezel  40  so the handle end  33  may engage with the bezel  40 . As illustrated in  FIG. 3   a , a surface of the second handle end  33  defines a slot  31  configured to engage with at least one side of the retainer  50 . The second handle end  33  also defines an opening  35  to engage with the axle  10 . This engagement is accomplished by the axle end  25  ( FIG. 5 ) being press fit into the opening  35 . 
         [0022]      FIG. 3   b  illustrates the retainer  50  engaged with the handle  30  in the handle slot  31 . The complementary shapes of the retainer  50  and handle slot  31  permit the retainer  50  to be maintained in position within the handle  30 . One of skill in the art will appreciate that the retainer  50  and handle slot  31  may embody many shapes that are complementary and provide the function of maintaining the retainer  50  engaged with the handle  30  in the handle slot  31 . Additionally, it is contemplated that the retainer  50  may be formed integral with the handle  30 . 
         [0023]      FIGS. 4   a  and  4   b  depict top and bottom views of the retainer  50 . The retainer  50  defines an opening  56  and a slot  55  that extends radially from an edge of the retainer  50  and is in communication with the opening  56 .  FIG. 4   a  shows a top view of the retainer  50  and an edge portion  52  of the opening  56 , which may be squared-off. In contrast, as shown in  FIG. 4   b , which is a bottom view of the retainer  50 , the edge surface  51  of the opening  56  may be chamfered to facilitate insertion of the axle  10  through the retainer opening  56 . The diameter of the opening  56  is configured to be smaller than the diameter of the axle  10 . The slot  55  allows the diameter of the opening  56  to expand to permit the axle  10  to be inserted through the opening  56 . 
         [0024]    Referring to  FIG. 5 , axle  10  has a first end  25  and a second end  20 . The second end  20  may be configured to engage a cable or a rod that is capable of transferring motion from the handle  30  to a door latch, for example, as known in the art. The first end  25  of the axle  10  includes a groove  63  and a lead-in  60 . The lead-in  60  defines a first side  61  and a second side  62 . The first side  61  is chamfered to facilitate installation of the axle  10  into the retainer  50  through opening  56 , while the second side  62  is squared-off to preclude the axle from being removed from the retainer  50  after assembly. The assembly of the axle  10  to the retainer  50  is further illustrated in  FIG. 7 . The axle  10  and handle  30  may be made of zinc or any other suitable material. 
         [0025]    Referring to  FIG. 6 , the lead-in  60  of the axle  10  may be configured to have a larger diameter than the retainer opening  56 . For the axle  10  to be installed into the retainer  50 , the retainer slot  55  allows the retainer opening  56  to expand to be larger than the diameter of the lead-in  60 . Once the axle  10  is located through the retainer  50 , the retainer opening  56  reduces to a diameter smaller than that of the lead-in  60 , and the retainer  50  rests in the axle groove  63 , as shown in  FIG. 7 . The lead-in square side  62  and the retainer square side  52  may then be in contact with each other to prevent the axle  10  from being removed from the door handle assembly  5  when fully assembled. 
         [0026]      FIG. 8  illustrates the axle  10  assembled to the handle  30  and retainer  50 . As illustrated, the end  25  of the axle  10  passes through and engages the retainer  50 , as described above (and further shown in  FIG. 7 ), and also engages and is press fit to the handle  30  through the handle opening  35  ( FIG. 3   b ), as described above. 
         [0027]    Consequently, with the configuration illustrated in  FIGS. 7 and 8 , the door handle system  5  which utilizes the retainer  50  may be prevented from becoming inoperable in the event the press fit between the axle and handle becomes loose, thus overcoming the known drawbacks with existing door handle systems. 
         [0028]    Variations and modifications of the foregoing are within the scope of the present invention. It should be 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. 
         [0029]    Various features of the invention are set forth in the following claims.