Patent Application
20180298648
The present disclosure relates generally to automobile door handle assemblies, and more particularly, the disclosure relates to a door handle assembly incorporating an integrated dual hinged sound dampening flap feature. The sound dampening flap of the present disclosure may be particularly useful in flush door handle assemblies. The sound dampening flap reduces noise when the handle is depressed.
In known flush vehicle door handles, there is typically a metal screw connected to an outer support plate that rests on a metal flap. The metal flap, in turn, rests on a spring. The tension from the spring acts to bias the handle to its resting condition. In this arrangement, the metal flap acts to reduce undesired noise which may be caused by metal to metal contact between the screw and the spring when the handle is depressed. In this prior construction, the sound dampening flap is typically integrated into the door handle assembly using a three-piece arrangement made up of the spring housing, a retaining pivot pin and the flap.
While prior door handles incorporating such a three-piece sound dampening arrangement may be highly functional, the construction of such structures may be relatively complex and require substantial skill. Specifically, such structures may require multiple tools to produce the individual components and a labor-intensive assembly procedure must be used to join the small pieces into the three-piece construction. Accordingly, a sound dampening system which reduces complexity and labor while maintaining functionality would provide a useful advantage over the prior art.
The present disclosure provides advantages and alternatives over the prior art by providing an improved sound dampening flap feature incorporated integrally within flush door handles. The improved sound dampening flap feature incorporates an integrated dual hinged flap. This dual hinge flap eliminates the need for any pivot pin or other retaining component thereby substantially simplifying the construction.
In accordance with one exemplary feature, the present disclosure provides a vehicle door handle assembly including a support plate disposed in overlying relation to a biasing spring. The support plate includes an exterior face projecting away from the biasing spring and a back face projecting towards the biasing spring. A transverse passageway extends across a thickness dimension of the support plate between the exterior face and the back face. A male member such as a fastener, rod, or the like is disposed in inserted relation within the transverse passageway. The male member comprises a proximal base disposed between the biasing spring and the back face. A spring housing supports the biasing spring and includes a perimeter wall that at least partially surrounds the biasing spring. A dual hinged flap is integral with the spring housing. The dual hinged flap includes an upper surface facing towards the support plate and a lower surface facing away from the support plate. The dual hinged flap includes a first hinge disposed adjacent the perimeter wall and a second hinge spaced radially inward from the first hinge. The dual hinged flap further includes a distal tab portion spaced apart from the perimeter wall such that the first hinge and the second hinge are disposed between the distal tab portion and the perimeter wall and wherein the distal tab portion is disposed in sandwiched relation between the biasing spring and the proximal base of the male fastener.
Other features and advantages of the disclosure will become apparent to those of skill in the art upon review of the following detailed description, claims and drawings.
While exemplary features of the disclosure are illustrated and will hereinafter be described in connection with certain potentially preferred embodiments and practices, it is to be understood that in no event is the disclosure limited to such illustrated and described embodiments and practices. On the contrary, it is intended that the present disclosure shall extend to all alternatives and modifications as may embrace the general principles of this disclosure within the full and true spirit and scope thereof.
Before an embodiment of the disclosure is explained in detail, it is to be understood that the disclosure 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 disclosure 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 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.
Exemplary features of the present disclosure will now be described through reference to the various figures, wherein to the extent possible like elements are designated by like reference numerals in the various views. Referring now to the drawings,
In the illustrated exemplary construction, the outer support plate 12 is substantially planar and provides a protective structural support covering for internal components of the door handle assembly 10 including a hooking latch 20 and complementary wire 22 which operate in a well-known manner during operation of the door handle assembly 10. In this regard, during operation of the door handle assembly 10, the hooking latch 20 may be caused to engage and lift the wire 22 during an opening procedure. Of course, other constructions may likewise be used if desired.
In the illustrated exemplary construction, the outer support plate 12 includes an exterior face 24 with a plurality of cutouts 26 disposed therein for access to the underlying operative components of the door handle assembly 10. By way of example only, and not limitation, the outer support plate may be formed as a unitary structure from a suitable plastic material such as acetal resin, Nylon 6, polyester or the like using techniques such as injection molding and the like. However, it is also contemplated that other structural materials such as metals, composites, and the like may likewise be utilized if desired.
As illustrated in the rear view of
In the illustrated exemplary construction, the outer support plate 12 includes a transverse passageway extending across the thickness dimension of the outer support plate 12. The transverse passageway defines a female opening for acceptance and retention of a male fastener 40 or other male member such as a pin or the like as best seen in
By way of example only and not limitation, in the illustrated exemplary construction the male fastener 40 may include a proximal base 42 positioned at the interior of the door handle assembly 10 and a distal end 44 disposed at the exterior of the outer support plate 12 (
Referring to
As illustrated, in the exemplary construction, the dome spring 54 may be supported within a spring housing 56 of generally annular construction having a perimeter wall 58 which at least partially surrounds the outer edge of the dome spring 54. In this regard, the outer edge of the dome spring 54 may be held within a circumferential retaining groove at the interior of the perimeter wall 58. As shown, the inner diameter of the retaining slot may be slightly greater than the outer diameter of the done spring 54 while nonetheless substantially constraining the dome spring 54 against radial or vertical displacement.
In operation, the dual hinged flap 52 operates to substantially suppress vibration-induced sound which may otherwise result from the interaction between the male fastener 40 and the dome spring 54 during operation. In accordance with one exemplary practice, the dual hinged flap 52 may be formed integrally with the spring housing 56 as a unitary structure by techniques such as injection molding or the like such that the spring housing 56 and the dual hinged flap 52 cooperatively form a unitary construction made from a single material. Materials of construction for the spring housing 56 and the dual hinged flap 52 preferably include polymeric materials such as acetal resin, Nylon, polyester, and the like having suitable pliability and toughness to incorporate living hinges without failure. However, other constructions and materials may likewise be used if desired. In particular, it is contemplated that different materials may be used to form the spring housing 56 and the dual hinged flap 52 if desired. By way of example only, and not limitation, such a construction incorporating different materials may be formed using techniques such as multi-shot molding or the like.
In the illustrated exemplary construction, the dual hinged flap 52 incorporates a pair of molded-in living hinges disposed between the perimeter wall 58 and the distal tab portion 55. In this regard, in the illustrated exemplary construction, a first hinge 60 is located at a proximal position adjacent the perimeter wall 58 substantially at the intersection of the dual hinged flap 52 with the spring housing 56. In this embodiment, a second hinge 62 is positioned radially inboard from the first hinge. As shown, in the exemplary construction, the first hinge 60 establishes an operative bending connection between the dual hinged flap 52 and the spring housing 56. The second hinge 62 facilitates parallel vertical movement of the distal tab portion 53 when the handle is depressed such that the distal tab portion may move up and down while retaining a substantially planar orientation between the male fastener 40 and the dome spring 54 during operation.
As noted previously, in the illustrated exemplary construction, the first hinge 60 and the second hinge 62 may be molded-in living hinges arranged on opposite sides of the dual hinged flap 52. As shown, in the exemplary construction, the first hinge 60 may be defined by a scalloped depression on the upper face 51 and the second hinge 62 may be defined by a scalloped depression on the lower face 53. However, it is likewise contemplated that the first hinge 60 and the second hinge 62 may be arranged on the same side of the flap 52 if desired. In this regard, it will be understood that the term “living hinge” refers to a hinge which operates by controlled bending of a structure rather than by the use of additional mechanical hinge structures. While such structures may be formed using the illustrated scalloped surface depressions, it is likewise contemplated that suitable living hinges formed by introducing angled notches, slits, or reduced thicknesses may likewise be used if desired
In operation, when the handle is opened, the male fastener 40 will apply a downward compressing force against the dome spring 54. In this condition, the dome spring will apply an opposing recovery force against the male fastener 40 thereby urging the handle to the resting, closed position. During this operation, the dual hinged flap 52 acts to reduce undesired vibration noise as the handle is depressed. Unlike prior constructions, no pivot pin or other mechanical retaining device is required to operate the dual hinged flap 52. Rather, the dual hinged flap 52 makes use of an integral connection to the spring housing 56 and a pair of bending living hinges 60, 62.
As the male fastener moves downward, the distal tab portion 55 of the dual hinged flap 52 may remain in substantially planar engagement against the dome spring 54 while moving vertically as the living hinges 60, 62 undergo bending to accommodate such vertical movement. In this regard, as the distal tab portion 55 moves vertically downward, the second hinge 62 may be caused to open up while the dual hinged flap 52 flexes at the first hinge 60 to accommodate this opening. Likewise, as the distal tab portion 55 moves vertically upward, the second hinge 62 may be caused to close, while the dual hinged flap 52 flexes at the first hinge 60 to accommodate such closing. Such adjustments may take place substantially continuously during use to adjust to vibration induced vertical movements. Surprisingly, it has been found that such a structure maintains integrity over an extended period of use despite the high level of cyclical bending. Moreover, the dual hinged flap may retain its desired orientation even in the presence of significant vertical movement of the overlying and underlying structures. Thus, the dual hinged flap is suitable to dampen vibration over a wide range of operating conditions.
Of course, variations and modifications of the foregoing are within the scope of the present disclosure. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context.
The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.
All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
This non-provisional application claims the benefit of, and priority from, U.S. provisional patent application No. 62/243,361 having a filing date of Oct. 19, 2015. The contents of such priority application are hereby incorporated by reference in their entirety as if fully set forth herein.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2016/050365 | 9/6/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62243361 | Oct 2015 | US |
