Snap-on Door Handle Assembly

This invention relates to motor vehicle door handle assemblies and more particularly to a method of attaching a motor vehicle door handle assembly to the associated motor vehicle door structure.

Motor vehicles typically include one or more doors providing access to the interior of the vehicle and at least one door handle assembly mounted on an interior and/or exterior surface or skin of each door to control the opening and closing of the door. The door handle assembies are typically attached to the associated door utilizing various fastener mechanisms and various tools. Although the fastener mechanisms and tools are effective in securing the door handle assembly to the door, they require that a considerable amount of high priced labor be expended in attaching each door handle assembly to each associated door. In an effort to minimize the required labor, door handle assemblies have been proposed which allow the handle assembly to be attached to the door without the use of separate fastening devices or tools and with a minimum of labor. See for example U.S. Pat. No. 5,758,454 assigned to the Assignee of the present invention and U.S. Pat. No. 5,183,302. This invention provides an alternate method and structure for fastening a motor vehicle door handle assembly to a motor vehicle door without the use of fasteners or tools and with a minimum of labor.

This invention is directed to the provision of an improved method and structure for attaching a motor vehicle door handle assembly to a motor vehicle door.

More particularly, this invention is directed to the provision of an improved method and structure for attaching a motor vehicle door handle assembly to a motor vehicle door without the use of separate fastening devices and without the use of tools.

The invention provides a method of mounting a motor vehicle door handle assembly on a skin of a door assembly of a motor vehicle wherein the handle assembly includes a handle member and a base plate defining a planar surface. According to the invention, a plurality of individual, spaced lug apertures and a separate spaced clip aperture are provided in the door skin; a plurality of lugs are provided on the handle base plate each sized to pass through a respective lug aperture in the door skin and each defining a web portion extending outwardly from the planar surface and a flange portion rigid with the web portion and spaced outwardly from the planar surface by at least the thickness of the door skin; a spring clip device is provided on the handle base plate biased outwardly from the planar surface and including a latching free edge for latching coaction with a latching edge of the clip aperture, the spacing and orientation of the lug and clip apertures relative to the spacing and orientation of the lugs and the spring clip being such that with each lug positioned in alignment with a respective lug aperture the spring clip is off-set with respect to the clip aperture; the door handle assembly is placed on the door skin with the planar surface of the base plate juxtaposed to an outer surface of the skin, the lugs passing through respective lug apertures, and the spring clip biased against a portion of the skin outer surface adjacent the clip aperture; and the door handle assembly is moved relative to the skin in a direction to move the web portion of each lug into engagement with an edge portion of a respective lug aperture, move the flange portion of each web beneath an inner surface of the skin proximate the respective lug aperture, and snap the free edge of the spring clip into latching engagement with the latching edge of the clip aperture. This methodology allows the handle assembly to be mounted on the door without the use of separate fastening devices, without the use of special tools, and with a minimum of labor.

According to a further feature of the invention, two laterally spaced lugs are provided proximate one end of the base plate, at least one lug is provided proximate another end of the base plate, and the spring clip device is provided proximate the one end of the base plate between the two laterally spaced lugs. This specific map of the apertures, lug and spring device provides a simple but yet firm interlocking coaction between the door assembly and the door skin.

According to a further feature of the invention, the base plate is formed as a molded plastic product, including a main body planar section, and the spring clip device is positioned in an aperture in the main body planar section of the base plate and is connected to the main body planar section of the base plate by a live hinge. This specific live hinge construction provides a positive snap action assembly while minimizing the cost of the assembly.

According to further feature of the invention, the clip aperture in the door skin coacting with the spring clip device defines a notch or cut-out in an edge thereof opposite the latching edge and the spring clip device includes a post that is received in the cut-out with the spring clip in latching engagement with the door skin. The coaction between the post and the cut-out ensures that the clip aligns precisely with the latching edge of the clip aperture and discourages inadvertent dislodgement of the spring clip from the door skin.

FIG. 1 is a perspective view of a motor vehicle door including a motor vehicle door handle assembly according to the invention shown in exploded relation with respect to an associated skin of the door;

FIG. 2 is a perspective view of the door handle assembly of the invention;

FIG. 3 is a fragmentary view taken within the circle 3 of FIG. 1;

FIG. 4 is a cross sectional view taken on line 4--4 of FIG. 2.

FIGS. 5, 6, and 7 are sequential views illustrating the attachment methodology of the invention.

The invention methodology and structure are especially suitable for attaching a motor vehicle door handle assembly to the inner or outer skin of a motor vehicle door.

The motor vehicle door 10, seen in FIG. 1, comprises the right rear door of a four door sedan type motor vehicle and includes a window opening 10a and an inner door skin 11. Inner skin 11 defines an outboard face 11a confronting the passenger compartment of the motor vehicle and an inboard face 11b confronting the interior of the door.

Door handle assembly 12 includes a base plate 14 and a door handle 16.

Base plate 14 is formed as a molded plastic product including a main body planar section 14a, laterally spaced posts 14b upstanding from the outboard face 14c of the main body planar section, lugs 14d, 14e, and 14f extending outwardly from the inboard face 14g of the main body planar section, and a spring clip 14h.

Lugs 14d, 14e, and 14f are triangulated on main body section 14a. Lugs 14d and 14e are positioned in laterally spaced relation proximate the forward edge 14h of the main body planar section and lug 14f is positioned proximate the rear edge 14i of the main body planar section.

Each lug 14d, 14e, and 14f defines a web portion 14j extending outwardly from the planar inboard face 14g and a rectangular flange portion 14k rigid with the web portion and spaced outwardly from the planar face 14g by approximately the thickness of skin 18. Each lug 14d, 14e, and 14f will be seen to open rearwardly and will be seen to be associated with a rectangular aperture 14l in the main body planar section.

Spring clip 14h has a generally rectangular configuration, is formed integrally with main body planar section 14c, is positioned in a rectangular aperture 14m in the main body section, is connected to the main body section by a living hinge 14n, exends forwardly in cantilever fashion from the living hinge, includes a post 14b, and is positioned generally between lugs 14d and 14e in longitudinal alignment with lug 14f. The free cantilevered end 14q of the spring clip defines a latching free edge 14r.

Handle 16 is pivotally mounted at one end 16a between spaced posts 14b by a pivot pin 18 and operates, in known manner, an associated latching mechanism for opening and closing the door.

Lugs 14d, 14e and 14f and spring clip 14h are adapted to coact with aperture means in the door skin 11 to attach the door handle assembly to the door skin.

Specifically, as best seen in FIGS. 1 and 3, the aperture means in the door skin 11 include a rectangular aperture 11c for coaction with lug 14d; a rectangular aperture 11d for coaction with lug 14e; a rectangular aperture 11e for coaction with lug 14f; and a rectangular aperture 11f for coaction with spring clip 14h. Lug apertures 11c, 11d, and 11e are triangulated and clip aperture 11h is positioned laterally between and rearwardly of lug apertures 11c and 11d.

Apertures 11c, 11d, 11e, and 11f are sized and configured to respectively pass lugs 14d, 14e, 14f and spring clip 14h. The spacing and orientation of the skin apertures relative to the spacing and orientation of the handle lugs and the handle spring clip are such that with each lug 14d, 14e, and 14f positioned in alignment with a respective aperture 11c, 11d, 11e, spring clip 14 is forwardly offset with respect to aperture 11f.

The manner in which the door handle assembly is attached to the door skin according to the methodology of the invention is best seen in sequential FIGS. 5, 6 and 7.

It will be understood that, for purposes of clarity, in FIGS. 5, 6, and 7 the spring clip 14 and the coacting aperture 11f have been moved rearwardly relative to lugs 14d, 14e and coacting apertures 11c and 11d. The true relative locations of the lugs and apertures and the spring clip are shown in FIGS. 1-4.

To attach the door handle assembly to the door skin 11, main body planar section 14c is positioned (FIG. 5) proximate the outboard face 11a of inner door skin 11 with lugs 14d, 14e, and 14f overlying apertures 11c, 11d, and 11e and spring clip 14h bearing resiliently at its free end 14q against skin face 11a forwardly of aperture 11f; whereafter (FIG. 6) main body planar section 14c is moved inwardly relative to the inner door skin to pass the lugs 14d, 14e, and 14f through apertures 11c, 11d, and 11e and flex spring clip 14h about its hinge axis 14n; whereafter (FIG. 7) main body planar section 14c is slid rearwardly to move the web portions 14j of the lugs into engagement with rear edge portions 11g of the associated skin aperture while moving the flange portion 14k of the lug beneath the inner surface 11b of the skin rearwardly of the respective aperture.

As the web portions 14j move into engagement with aperture rear edges 11g, spring clip 14h snaps inwardly into aperture 11f and, specifically, the latching edge 14r proximate the cantilevered free end 14q of the spring clip snaps into latching engagement with the forward latching edge 11h of the aperture 11f while post 14p is received in a cut-out or notch 11i formed in the rear edge 11j of aperture 11f to ensure that the clip edge 14r aligns precisely with aperture edge 11f and discourage dislodgement of the spring clip from the door skin.

It will be seen that, in one simple swiping movement of the door handle assembly over the door skin, the door handle assembly is firmly and positively attached to the door skin, thereby minimizing the amount of time and labor required to mount the door handle assembly on the door skin and eliminating the need for special tools or fasteners to accomplish the mounting operation, and yet providing a firm positive locking attachment of the door handle assembly to the door skin.

In the mounted configuration of the door handle assembly on the door skin, rearward movement of the door handle assembly relative to the skin is precluded by engagement of latching edge 14r with aperture edge 11h; forward movement of the door handle assembly relative to the skin is precluded by engagement of lug web portions 14j with aperture edges 11g; outward movement of the door handle assembly relative to the skin is precluded by engagement of the flange portions of the lugs with the adjacent surfaces of the skin inboard face 11b; and up and down movement of the door handle assembly relative to the skin is precluded by the combined action of the lug web portions against the adjacent aperture edge portions and the engagement of the spring clip free end portion 14q with the front transverse edge 11h of aperture 11f.

Removal of the door handle assembly from the door skin cannot be achieved from inside of the vehicle but rather can be readily achieved by a suitable tool inserted into the interior of the door behind the inner skin to move the clip 14h outwardly and free the clip from engagement with edge 11h whereafter the door handle assembly may be slid forwardly to disengage the lugs from the respective aperture surfaces and allow separation of the door handle assembly from the door.

The invention methodology will be seen to provide a rapid and efficient means of attaching a door handle assembly to a skin of the motor vehicle door with a minimum of labor and without resort to separate fasteners or tools.

Whereas a preferred embodiment of the invention has been illustrated and described in detail it will be apparent that various changes may be made in the disclosed embodiment without departing from the scope or spirit of the invention.