Patent Application
20150039180
The subject matter described herein concerns exterior features used on a vehicle, and more particularly to the controller and sensors used in a vehicle door handle.
Most modern vehicles require some type of exterior door handle to open and close the vehicle doors. The conventional exterior door handle is mounted over a recessed area in the door creating a finger opening or place to insert one's hand while unlocking and opening the door. The exterior door handle spans this recessed area in the door and incorporates a mechanical hinge, a paddle, or other mechanical actuator to engage the latch and open the door. As the exterior door handle pivots on the mechanical actuator, the door latch mechanism for the vehicle door is actuated causing the door to unlatch and open.
Generally, the conventional mechanical door handle also has a corresponding interior mechanical assembly mounted within the interior of the door. This interior mechanical assembly may incorporate rods, flanges, or other mechanical components to engage a lock mechanism for locking/unlocking the door and/or a latch mechanism to open the door. In addition to the interior mechanical assembly for the door handle, the interior of the door may also need room for a retracted glass window and the corresponding mechanical or electromechanical components for moving the window up and down.
To accommodate different vehicle door designs, it is useful to have more room on the interior of the door. With additional room, the vehicle door may be equipped with more sophisticated door handles, stronger structural support, a more streamlined profile, or other features. This may be accomplished by reducing the size of the interior mechanisms or by replacing the mechanical assemblies in part or in whole with controllers and electronics.
Aspects of the disclosure provide a door handle assembly used in a vehicle and controlled using a controller and one or more sensors. When not in use, a door handle in the door handle assembly is retracted into the door with a planar surface of the door handle remaining flush with the outer surface of the door. When a person pushes in on the flush door handle, a retraction force sensor in the door handle assembly detects the inward force, and the controller responds by instructing a motor to extend the door handle. If a hand pulls on the extended handle, an extension force sensor detects the pulling force and the controller responds by instructing a latch on the door to unlatch and open the door.
In some embodiments, the door handle assembly includes a door handle formed from a planar handle member having a first post portion and a second post portion. An upper portion of a swing arm located in the interior of the vehicle door is connected near a distal portion of the first post portion of the door handle and a distal portion of the second post portion of the door handle. The lower portion of the swing arm is rotably attached to a shaft mounted to an inner door surface of the vehicle door allowing the swing arm to pivot between an extended position and a retracted position. An extension force sensor fixedly attached to the inner door surface of the vehicle door generates an extension force response signal when the extension force sensor comes into contact with the upper portion of the swing arm. A retraction force sensor fixedly attached to the lower portion of the swing arm generates a retraction force response signal when the retraction force sensor on the lower portion of the swing arm comes into contact with a flush adjuster rod. A handle controller processes both the extension force response signal received from the extension force sensor and the retraction force response signal received from the retraction force sensor in controlling the operation of the door handle in the door handle assembly.
To facilitate the door handle retracting into the vehicle door, the handle controller runs a motor operatively coupled to a door handle. As the door handle retracts, the swing arm coupled to the door handle also retracts into the vehicle door and presses against the retraction force sensor with a first retraction force—this creates a first retraction force signal response. The handle controller may stop the motor if the first retraction force signal indicates the door handle is fully retracted. In some embodiments, the handle controller determines the door handle is retracted when the first retraction force corresponding to the first retraction force signal is greater than a retraction stop threshold. Subsequently, the handle controller may receive and process a second retraction force signal response as a result of an inward push on the door handle and the swing arm pressing against the retraction force sensor a second time. In response to the second retraction force signal, the handle controller instructs the motor operatively coupled to the door handle to facilitate extending the door handle from the retracted position into an extended position from the vehicle door.
Further embodiments of the handle controller process the extension force signal while extending the door handle from the vehicle door. To facilitate the door handle extending from the vehicle door, the handle controller runs a motor operatively coupled to a door handle. As the door handle extends, the swing arm coupled to the door handle also extends from the vehicle door and presses against the extension force sensor—this creates a first extension force signal response. The handle controller may stop the motor if the first extension force signal indicates that the handle is fully extended. In some embodiments, the handle controller determines that the handle is fully extended when the first extension force signal is greater than an extension stop threshold. Subsequently, the handle controller may receive and process a second extension force signal response as a result of a hand pulling on the door handle and the swing arm coupled to the door handle pressing against the extension force sensor a second time. In response to the second extension force signal, the handle controller may in turn request unlatching a latch holding the vehicle door shut, and allowing the vehicle door to open.
In the following detailed description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the various embodiments of the disclosure. Those of ordinary skill in the art will realize that these various embodiments are illustrative only and are not intended to be limiting in any way. Other embodiments will readily suggest themselves to such skilled persons having the benefit of this disclosure.
In addition, for clarity purposes, not all of the routine features of the embodiments described herein are shown or described. One of ordinary skill in the art would readily appreciate that in the development of any such actual implementation, numerous implementation-specific decisions may be required to achieve specific design objectives. These design objectives will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine engineering undertaking for those of ordinary skill in the art having the benefit of this disclosure.
Referring to
In the retracted position depicted in
To further enhance the overall comfort, safety, and appearance, some embodiments of door handle 104 are formed by coupling a handle base member 110 to planar handle member 104C at the distal portions of first post portion 104B and second post portion 104A. In the deployed state, planar surface of handle base member 110 extending between first post portion 104B and second post portion 104A may also be substantially flush with surrounding areas of outer door surface 100. The resulting smooth contiguous surface presented as a hand is inserted in the wrapped handle grip 112 engenders quality and integrity, both visually and practically, in the operation of door handle 104 and the vehicle to which it is attached.
To give the door handle 104 the appearance of gradually floating into position, several different subcomponents or assemblies are used under the direction of a combination of one or more controllers as depicted and described in
By securely attaching handle base member 110 to door handle 104 with handle fasteners 202E, both the door handle 104 and handle base member 110 move together when urged by a swing arm 202. Swing arm 202 in one embodiment has both an upper dual fork portion 202A and a lower dual fork portion 202B, and may be referred to as a “swan neck fork” arm due to the widely spaced arcuate forks. In this embodiment, the shape of each arcuate fork and the width between forks provide a stiffness that reduces torsional displacement and linear deflection when the door handle 104 is used. As the term “arcuate” refers to all or portions of a circular line, it is contemplated that the arcuate shapes of dual forks in upper dual fork portion 202A and lower dual fork portion 202B, as well as the width between each fork, may be modified depending on the particular shape of the door and other implementation details.
From upper dual fork portion 202A, a first upper fork 202C is rotably coupled to a backside of handle base member 110 near the distal portion of the second post portion 104A. Likewise, a second upper fork 202D from the upper dual fork portion 202A is also rotably coupled to the backside of the handle base member 110 near the distal portion of the first post portion 104B. In some implementations, both second upper fork 202D and first upper fork 202C fit into slotted openings 2021 within handle base member 110. A smaller shaft passes through axial openings in the walls of each slotted opening 2021 and the ends of each upper dual fork portion 202A, this enables the door handle 104 and handle base member 110 to pivot about the upper portion of swing arm 202.
In some embodiments, lower dual fork portion 202B pivots about a shaft 208 slidably inserted through corresponding axial openings in handle assembly tray 304. If an assembly tray 304 is not utilized to mount door handle assembly 200, shaft 208 may alternatively be axially attached through openings made directly in the inner door surface 302. In either embodiment, once the lower dual fork portion 202B is rotably attached to shaft 208, pivoting of the swing arm 202 also results in movement of the door handle 104 and handle base member 110. In particular, as the swing arm 202 pivots around shaft 208, the upper dual fork portion 202A of the swing arm 202 moves portions of door handle 104 between outer door surface 100 and inner door surface 302. For example, moving the swing arm 202 towards the inner door surface 302 causes door handle 104 to extend through handle aperture 102, this positions the door handle 104 above the outer door surface 100. Conversely, moving the swing arm 202 away from the inner door surface 302 urges the door handle 104 to retract through the handle aperture 102, this eventually results in retracting the planar handle member 104C until it is flush with the outer door surface 100.
As the door handle 104 extends and retracts through handle aperture 102, control arm 206 keeps its motion along a parallel direction. The precision and predictability of this parallel motion compliments the overall design and further engenders an impression of reliability, integrity, and craftsmanship of the vehicle handle 104 and the vehicle in which it used. The parallel motion of the door handle 104 also helps accommodate a tight packaging requirement within the door while providing a wrapped handle grip 112 with adequate clearance for fingers and a hand. Within the interior of the car door, for example, the swing arm 202 can retract door handle 104 without damaging a retracted window of the car door. In some embodiments, an upper control arm pivot 206B rotably connected to the backside of the handle base member 110 is positioned off-axis to the rotably coupled second upper fork 202D. Similarly, a corresponding lower control arm pivot 206A is rotably connected to the inner door surface 302 of the vehicle door and positioned off-axis to the rotably coupled second lower fork 202H. Combined together, the off-axis positioning of control arm 206 relative to swing arm 202 creates a four-bar link for controlling motion of door handle 104. In one embodiment, the control arm 206 controls the longitudinal rotation of the vehicle handle 104 and constrains the vehicle handle 104 movement along a parallel direction from outer door surface 100.
A biasing member 204, implemented in some embodiments with springs, operates to urge door handle 104 into a retracted position flush with the outer door surface 100. Coiled portions of the springs from biasing member 204 are wrapped around shaft 208 while tails of the springs are inserted into spring insertion points 202F. While the force imparted by biasing member 204 urges the swing arm 202 to retract, it is not strong enough to pinch or hurt a hand inserted into wrapped handle grip 112 of door handle 104. Consequently, if a hand is inside wrapped handle grip 112, biasing member 204 may partially retract the door handle 104 towards the inner door surface 302 stopping when the person's hand meets the handle aperture 102.
To extend the vehicle handle 104, one embodiment of door handle assembly 200 utilizes a handle motor 318 and various drive components, A motor mount 306 in the door handle assembly 200 receives the handle motor 318 with a drive shaft passing through motor shaft opening 308. Drive gear 312 is axially mounted on the drive shaft and, when positioned in drive gear slot 310, engages with and meshes to gears from a paddle gear 314. By mounting paddle gear 314 about shaft 208 and rotating handle motor 318 in a first direction, the gears are advanced and the opposing face of the paddle, at the distal end, slidably engages first lower fork 202G. The force imparted upon first lower fork 202G overcomes the opposing force from biasing member 204 thus urging swing arm 202 towards the inner door surface 302 and moving door handle 104 into an extended position.
In some embodiments; the handle motor 318 stops rotating in the first direction when the upper dual fork portion 202A applies pressure to extension sensor 402, this condition indicates the door handle 104 is fully extended. To keep the vehicle handle in this extended position, a handle controller 616 monitoring extension sensor 402 instructs the handle motor 318 to stop rotating in the first direction. Planetary gears incorporated in handle motor 318 resist retracting vehicle handle 104, even under the force imparted from biasing member 204.
The handle controller 616 may subsequently instruct handle motor 318 to rotate in the second direction, opposite the first rotational direction, thereby overcoming the torque of the planetary gears and allowing biasing member 204 to retract vehicle handle 104. The chance of pinching fingers or hands in wrapped handle grip 112 is reduced as the flat side of paddle gear 314 drops away from first lower fork 202G and only the force of biasing member 204 retracts vehicle handle 104. The handle controller 616 instructs the handle motor 318 to stop rotating in the second direction when the lower dual fork portion 202B applies sufficient pressure on retraction sensor 320, this condition indicates the door handle 104 is fully retracted. In various embodiments, extension sensor 402 and retraction sensor 320 may be implemented using a variety of mechanical, electromechanical, solid-state, magnetic, nano-particle, piezo-electric based technologies capable of detecting a force, a change in force, a distance traveled, a change in electrical resistance, deformation or other events producing results that may be detected and processed by handle controller 616.
Retraction sensor 320 is fixedly mounted on a sensor flange 210 located between the first lower fork 202G and second lower fork 202H of lower dual fork portion 202B. In some embodiments, placing sensor flange 210 and retraction sensor 320 equidistant from the first lower fork 202G and second lower fork 202H helps maintain even pressure on retraction sensor 320. A flush adjuster rod 316 placed through a longitudinal slot or aperture in retraction sensor 320 limits how far swing arm 202 may retract. The flush adjuster rod 316 passes through both retraction sensor 320 and sensor flange 210 into a threaded opening 404 of the inner door surface 302. The size of annular flange 316A is sufficiently large to evenly distribute force from swing arm 202 over the face of retraction sensor 320. Some embodiments may integrate the annular flange 316A into the top of flush adjuster rod 316 or by axially sliding a washer or gasket into place over the flush adjuster rod 316. To fit door assembly 200 into a vehicle door during manufacture, the flush adjuster rod 316 is axially adjusted against the force of biasing member 204 until the surface of planar handle member 104C is flush with the outer door surface 100.
The door handle system 600 in one embodiment includes retraction sensor 320, handle motor 318, extension sensor 402, handle controller 616, and handle illumination 618. Typically, handle controller 616 receives sensor data from retraction sensor 320 or extension sensor 402 then uses the results to determine whether to extend or retract the door handle 104. Handle controller 402 may also use vehicle status information from door controller 604 and vehicle controller 602 in determining when to extend or retract door handle 102. For example, if vehicle controller 602 indicates a vehicle is moving, then door handle system 600 may not extend door handle 104. In general, handle controller 616, door controller 604, and vehicle controller 602 may include one or more embedded or general purpose processors running a variety of software or firmware configured to control door handle 104 and operation of other various portions of the vehicle.
When door handle 104 is retracted as illustrated in
In the event door handle 104 is extended as depicted in
Referring to
In part, integrated force sensor 700 is advantageous as it may be connected to handle controller 616 using a single force sensor connector 700E. This reduces costs by avoiding multiple connections, duplicative wiring, and added space required for multiple connectors on handle controller 616 and within the handle assembly 200. As another advantage, the flexible interconnection 700F formed between the max force sensor 700A and min force sensor 700C bends smoothly as swing arm 202 extends and retracts. Strain on integrated force sensor 700 is reduced as the swing arm 202 moves along the length of the flexible circuitry. In alternate embodiments not using integrated force sensor 700, extension force sensor 700A and retraction force sensor 700C may instead be discrete sensors with individual flexible circuitry interconnections (not shown) to handle controller 616 rather than the single force sensor connector 700E. Accordingly, the aforementioned advantages are meant to be illustrative, not limiting, and other alternate embodiments may include greater or fewer of the aforementioned advantages or may included additional advantages implied but not mentioned expressly herein.
In some embodiments, the portion of integrated force sensor 700 incorporating extension force sensor 700A is fixedly attached to the inner door surface 302 within handle assembly tray 304. For example, an adhesive material resilient to heat, cold, moisture, and other conditions may be used to attach a segment of the integrated force sensor 700 to the inner door surface 302. The distal end of integrated force sensor 700 passes under swing arm 202 and plugs into handle controller 700 through single force sensor connector 700E.
To enhance operation of extension force sensor 700A, an extension sensor puck 700B may be fixedly attached to a surface of the extension force sensor 700A. The extension sensor puck 700B provides a uniform area for an upper portion of the swing arm 202 to contact with the underlying extension force sensor 700A. Covering extension force sensor 700A in this manner also improves reliability by reducing direct contact with, and associated wear of, the sensor.
Retraction force sensor 700C is located at the proximal end of integrated force sensor 700 and sandwiched between plate clamps 702. While plate clamps 702 align retraction force sensor 700B, fasteners hold plate clamps 702 in a fixed position against sensor flange 210. In some embodiments, a retraction sensor puck (not illustrated) may be situated between retraction force sensor 700C and one or both of plate clamps 702. As previously described, the puck provides a uniform area for receiving pressure and improves predictability, reliability, and serviceability of the sensor. For example, each time swing arm 202 is retracted, the flush adjuster rod 316 transfers the resulting force through retraction sensor puck to retraction force sensor 700C. If retraction sensor puck becomes worn and handle assembly 304 needs service, the retraction sensor puck and/or the extension sensor puck 700B may be replaced rather than replacing the entire integrated force sensor 700.
In operation, extension force sensor 700A generates an extension force response signal when swing arm 202 pivots about shaft 208 and is extended. The extension force response signal corresponds to a force created between the extension force sensor 700A and the upper portion of the swing arm 202. As illustrated in
Similarly, retraction force sensor 700C generates a retraction force response signal when swing arm 202 pivots about shaft 208 and is retracted. As illustrated in
Once the door handle 104 is retracted, retraction force sensor 700C may also generate another retraction force response signal when a user pushes in on the door handle 104. Typically, the retraction force response signal from the user pushing on the door handle 104 is greater than the force generated when the door handle 104 is retracted. In both instances, the retraction force sensor 700C generates the retraction force response signal as a result of the contact with the flush adjuster rod 316. As described in further detail later herein, the handle controller 616 receives and processes the retraction force response signals and determines whether the door handle 104 is moving into the retracted position or the user is pushing in on the door handle 104.
Handle operations 800B in
As the door handle 104 retracts into the vehicle door, some embodiments receive a first retraction force signal response from the retraction force sensor 700C (904). Swing arm 202 coupled to door handle 104 retracts into the vehicle door and presses against the retraction force sensor 700C. In some embodiments, the pressure or force detected occurs when the retraction force sensor 700C in plate clamps 702 comes in contact with flush adjuster rod 316.
If the first retraction force signal indicates the first retraction force is not greater than a retraction stop threshold, (906—No) the handle motor 318 continues to run allowing the door handle 104 to further retract into the vehicle door (902). Eventually, when the retraction force is greater than the retraction stop threshold (906—Yes), the motor is instructed to stop running as the door handle 104 has been sufficiently retracted (908). In some embodiments, the door handle 104 may be calibrated such that the planar surface of the door handle 104 is flush with the surface of the vehicle door when the first retraction force is greater than the retraction stop threshold.
With the door handle retracted, some embodiments receive a second retraction force signal response corresponding to a second retraction force applied to the retraction force sensor 700C (910). In most cases, the second retraction force occurs as a result of a hand pushing inward on the door handle 104, and the swing arm 202 pressing against the retraction force sensor 700C a second time. To confirm a hand has pushed on the door handle, some embodiments check if the second retraction force on the door handle 104 was greater than the first retraction force on the door handle 104. Other embodiments may also determine if the second retraction force is greater than the first retraction force by a minimum push threshold force. In addition, some embodiments may measure if the time period for the second retraction force has a minimum push pulse width to determine whether the second retraction force was from a person's hand. If it is determined that the second retraction force signal was from a hand pushing inward on the door handle, a controller 616 instructs the motor 318 to extend the door handle 104 from the retracted position into an extended position (912).
A flowchart diagram in
If the first extension force signal indicates the first extension force is not greater than a extension stop threshold, (1006—No) the motor 318 continues to run causing the door handle 104 to extend above the outer surface 100 of the vehicle door (1002). Eventually, when the extension force is greater than the extension stop threshold (1006—Yes), the motor 318 is instructed to stop running as the door handle 104 has been sufficiently extended (1008). In some embodiments, the minimum stop threshold corresponds to when the door handle 104 is fully extended from an outer surface 100 of the vehicle door.
With the door handle 104 extended, some embodiments receive a second extension force signal response corresponding to a second extension force applied to the extension force sensor 700A (1010). In most cases, the second extension force occurs as a result of a hand pulling on the door handle 104, and the swing arm 202 pressing against the extension force sensor 700A a second time. To confirm a hand has pulled the door handle, some embodiments check whether the second extension force was greater than the first extension force resulting from extending the door handle 104. Other embodiments may also compare the second retraction force with a minimum pull threshold force and the corresponding time period with a minimum pull pulse width to determine whether the second extension force is from a hand pulling on the door handle 104. Upon determining the door handle 104 was pulled, one embodiment instructs a latch holding the vehicle door shut to unlatch and allow the vehicle door to open (1012).
With respect to handle operations 800A, the schematic graph in
Retraction force sensor 700C at time t3 (1106) receives a second retraction force f3 (1106) as a result of a hand pushing inward on the door handle 104 and swing arm 202. To confirm the force is from a hand and not a false input due to mechanical vibration (e.g., objects hitting door, door slamming), some embodiments check if the increased force f3 (1106) on the door handle 104 was greater than a minimum push threshold F1 (e.g., f3>F1) Other embodiments may determine whether the second retraction force was from a person's hand by comparing the second retraction force f3 with both a minimum push threshold F1 (e.g., f3>F1) as well as a minimum push pulse width T0 (e.g., Δt34>T0) (1108). Eventually, when the door handle 104 is almost fully extended at time t5 (1110) it is no longer in contact with retraction force sensor 700C and the retraction force sensor response drops off.
Schematic graph in
Extension force sensor 700A at time t3 (1106) receives a second extension force f3 (1106) as a result of a hand pulling outward on the door handle 104 and swing arm 202. To confirm the pulling force is from a hand and not a false input due to mechanical vibration (e.g., objects hitting door, door slamming), some embodiments check if the increased force f3 (1106) on the door handle 104 was greater than a minimum pull threshold F1 (e.g., f3>F1). Other embodiments may determine whether the second extension force was from a person's hand by comparing the second extension force f3 with both a minimum pull threshold F1 (e.g., f3>F1) as well as with a minimum pull pulse width T0 (e.g., Δt34>T0) (1108). In some embodiments, handle controller 616 confirms a hand has pulled door handle 104 and instructs door controller 604 to unlatch the door. When the door handle 104 eventually retracts at t5(1110), the swing arm is no longer in contact with extension force sensor 700A and the extension force sensor response drops off.
While specific embodiments have been described herein for purposes of illustration, various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, the disclosure is not limited to the above-described implementations, but instead is defined by the appended claims in light of their full scope of equivalents.
This application claims the benefit of: (1) U.S. Provisional Application No. 61/539,203, filed Sep. 26, 2011, entitled, “DOOR RELEASE LATCH UTILIZING A CAPACITIVE SENSOR” by Wheeler et. al, (2) U.S. Provisional Application No. 61/539,337, filed Sep. 26, 2011, entitled, “SINGLE SOURCE DUAL PURPOSE, VEHICLE DOOR HANDLE ILLUMINATOR” by Wheeler et. al, (3) U.S. Provisional Application No. 61/539,499, filed Sep. 27, 2011, entitled, “ELECTRO-MECHANICAL SWITCH ASSEMBLY FOR EXTERIOR VEHICLE DOOR HANDLE” by Wheeler et. al, (4) U.S. Provisional Application No. 61/539,580, filed Sep. 27, 2011, entitled, “SELF-DEPLOYING OUTSIDE DOOR HANDLE” by Wheeler et. al, assigned to the assignee of this application and incorporated by reference herein for all purposes. Each of the above-referenced patent applications is incorporated by reference herein for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 20130079984 A1 | Mar 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| 61539499 | Sep 2011 | US | |
| 61539203 | Sep 2011 | US | |
| 61539337 | Sep 2011 | US | |
| 61539580 | Sep 2011 | US |
