Patent Document

FIELD OF THE INVENTION 
     The present invention generally relates to outside door handle assemblies for motor vehicles, and in particular to an outside handle assembly and bezel. 
     BACKGROUND OF THE INVENTION 
     Various types of exterior door handle assemblies for motor vehicles have been developed. A known type of handle utilizes a handle strap that is pivotably mounted to a handle reinforcement structure at a first end of the handle strap. A second end of the handle strap includes a hook or extension that is operably connected to a door latch by a rod or other suitable connecting arrangement. A handle bezel is attached to the handle reinforcement, and includes an outwardly facing finished surface that may include a pocket that receives a user&#39;s fingers behind the handle strap. Outward rotation of the handle by a user causes the rod to shift, thereby unlatching the door. The handle may include an inertia lock assembly including an inertia lock that rotates to a locked position to prevent outward rotation of the handle strap, and thereby prevent release of the latch when the handle assembly is subject to an acceleration force. 
     SUMMARY OF THE INVENTION 
     One aspect of the present invention is an exterior door handle assembly for motor vehicles. The handle assembly includes a bezel structure having inner and outer opposite sides and a peripheral portion extending around the bezel structure. A handle member is movably mounted to the bezel structure for movement between open and closed positions. The handle member is configured to be operably connected to a door latch to unlatch the door latch when the handle member is in the open position. The handle assembly further includes an inertia lock member movably mounted to a first portion of the bezel structure and moving from a rest position to an actuated position when subject to acceleration. The inertia lock member permits movement of the handle member from the closed position to the open position when the inertia lock member is in the rest position. The inertia lock member prevents movement of the handle member to the open position when the inertia lock member is in the actuated position. The handle assembly further includes a pushing surface on a second portion of the bezel structure. The first portion of the bezel structure defines a first bending strength, and the second portion of the bezel structure defines a second bending strength. The bezel structure includes an intermediate portion disposed between the first and second portions of the bezel structure defining a bending strength that is significantly less than the first and second bending strengths such that the intermediate portion of the bezel structure deforms and causes the pushing surface to contact the inertia lock member and prevent movement of the inertia lock member to its rest position when the bezel structure is subject to a bending force to thereby prevent movement of the handle member to its open position. 
     These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a partially fragmentary isometric view of a door handle assembly viewed from outside the vehicle; 
         FIG. 2  is a cross-sectional view of the door handle of  FIG. 1  taken along the line II-II; 
         FIG. 3  is a cross sectional view of the vehicle handle of  FIG. 1  taken along the line IV-IV;  FIG. 1 ; 
         FIG. 4  is a partially fragmentary view of a door handle after fracture of the handle reinforcement structure; 
         FIG. 5  is a cross sectional view of the handle assembly of  FIG. 4  taken along the line VI-VI; 
         FIG. 6  is a partially fragmentary isometric view of a handle assembly in an intact condition; 
         FIG. 7  is a partially fragmentary view of a handle assembly according to the present invention, wherein the bezel has been deformed/broken along a fracture line, thereby driving a push surface into an inertia lock member to thereby cause the inertia lock member to prevent the handle assembly from operating and releasing the latch. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     With reference to  FIG. 1 , a vehicle exterior door handle assembly  1  includes a handle strap  5  having a forward end  6  that is rotatably mounted to handle reinforcing structure  10  for rotation about a vertical pivot pin/axis  12 . A rearward end  7  of handle strap  5  includes a hook or plunger  8  (see also  FIG. 2 ) that connects to a bellcrank  15  in a known manner. Bellcrank  15  is operably connected to a vehicle latch  16  ( FIG. 2 ) by a mechanical connector such as a rod  17  (or cable) to thereby actuate the latch  16  upon movement of the handle strap  5 . Outward rotation of handle strap  5  as indicated by the arrow “A” ( FIGS. 1 and 2 ) rotates bellcrank  15  as shown by the arrow “B” ( FIG. 2 ), thereby releasing latch  16  via rod  17  in a known manner. 
     Referring again to  FIG. 2 , bellcrank  15  includes a first arm  20  having a counter-mass  22  rigidly connected to an outer end  24  of first arm  20 . Bellcrank  15  also includes a second arm  26  that is operably interconnected with hook or plunger  8  of handle strap  5  in a known manner. Bellcrank  15  pivots about a horizontal pin  28  to thereby rotatably interconnect bellcrank  15  with handle reinforcement structure  10 . In the event the handle assembly  1  experiences side acceleration that generates a force acting on handle strap  5  in the direction of the arrow A, a counter force A1 is generated by counter-mass  22 , thereby reducing or eliminating the tendency of handle strap  5  to shift outwardly. The construction of counter mass  22  and bellcrank  15  may be of a known design, and will therefore not be further described in detail herein. 
     Bellcrank  15  also includes a third arm  30  (see also  FIGS. 6 and 7 ) that comprises a counter-mass lever. Lever  30  is rigidly interconnected with arms  20  and  26 , and rotates therewith about pivot end  28 . An inertia lock lever  32  is rotatably interconnected to handle reinforcement structure  10  by a pin  34  for rotation about a vertical axis. An extension  36  of inertia lock lever  32  selectively rotates to a position directly adjacent third arm  30  of bellcrank  15  to prevent rotation of bellcrank  15  in the direction of the arrow B. A mass portion  38  of inertia lock lever  32  generates a force tending to pivot the inertia lock lever  32  about vertical axis V if a side acceleration is present, thereby causing the extension  36  to rotate into a blocked or locked position as shown in  FIG. 7  wherein the extension  36  prevents downward rotation/movement of third arm  30  of bellcrank  15 , thereby preventing rotation of bellcrank  15  in the direction of the arrow “B” ( FIG. 2 ). A spring (not shown) may bias the inertia lock lever  32  in an opposite direction to thereby shift the extension  36  to an unblocked position permitting movement of bellcrank  15  if no side acceleration is present. It will be understood that this aspect of inertia lock lever  32  may be substantially the same as known inertia lock devices. 
     With further reference to  FIGS. 3-7 , application of a force F on the handle assembly  1  (when installed in a motor vehicle) will cause handle reinforcement structure  10  to fracture along a fracture line or line of weakening  40  that is designed into handle reinforcement structure  10 . After the reinforcing structure  10  fractures, a fracture line or gap  48  ( FIG. 4 ) is formed where the line of weakening  40  ( FIG. 3 ) had been. Reinforcing structure  10  includes an extension  45  having a pushing surface  46 . When handle reinforcing structure  10  fractures along line of weakening  40 , it forms a first part  10 A, and a second part  10 B. The second part  10 B will tend to rotate relative to the first part  10 A to open the gap  48 , and handle strap  5  and bezel  11  will tend to remain attached to first portion  10 A of handle reinforcing structure  10 . As the first and second parts  10 A and  10 B of handle reinforcing structure  10  rotate, pushing surface  46  of extension  45  contacts end  50  of inertia lock lever  32 , thereby driving inertia lock lever  32  into a locked position wherein extension  36  of inertia lock lever  32  locks/prevents rotation of third arm  30  to thereby prevent rotation of bellcrank  15 . Thus, in the event the vehicle experiences a side impact in the vicinity of the handle assembly  1 , a force F due to the impact will tend to fracture reinforcing structure  10 , causing pushing surface  46  to push on inertia lock lever  32  to a locking position to thereby prevent unlatching of latch  16 . 
     With further reference to  FIG. 5 , reinforcing structure  10  may include a sidewall  52 , and end walls or lips  54 . Reinforcing structure  10  may include one or more internal reinforcing ribs  56  and/or reinforcing walls  58  or other such structures. The thicknesses of the sidewall  52  endwall  54 , reinforcing rib  56  and/or reinforcing wall  58  may be reduced in the vicinity of the fracture line  40  to create a line of weakening at which the handle reinforcing structure  10  fractures. Also, one or more of the reinforcing structures  56  and  58  may be discontinued in the vicinity of the line of weakening  40  to further ensure that the reinforcing structure  10  fractures along the line of weakening  40  in the event a force F is applied to the handle assembly  1 . It will be understood that the reinforcing structure  10  may have a variety of configurations shapes, etc. to accommodate the needs of a particular application. In the illustrated example, the handle reinforcing structure  10  is made of a molded polymer material, as is the bezel  11 . However, other materials may also be utilized, depending upon the requirements of a particular application. 
     The line of weakening  40  and push surface  46  ensure that the inertia lock lever  32  is pushed/shifted into a locked position to prevent unlatching of latch  16  in the event a force F is applied to the vehicle in the vicinity of handle assembly  1 . It will understood that the force F may cause fracture of handle reinforcing structure  10  and subsequent locking of inertia lock lever  32  if a sufficient force is present, regardless of whether or not a large lateral acceleration is present. 
     It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

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