BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to a door structure applicable to a back door of a
vehicle or the like, and in particular, relates to that having a switch for releasing
a door lock state at a handle part which is operated by hand in order to open the
door.
Description of the Related Art
[0002] A back door of a vehicle which has a lock release switch for releasing a door lock
state is known (see, for example,
Japanese Unexamined Patent Application, First Publication No. 2003-127668). This back door has a handle cover which is attached to a door frame panel and has
a recessed portion into which a hand is inserted for opening the door. The lock release
switch is attached integrally to the handle cover. Therefore, in this structure, lock
releasing and door opening can be performed by a series of operations such as inserting
a hand into the recessed portion and raising the door by hand.
[0003] However, in this conventional door structure, the lock release switch is provided
at the handle cover to which a force is applied when the door is opened. Therefore,
when the door is opened, almost all the load is applied to the lock release switch.
Accordingly, when employing the conventional door structure, the lock release switch
must have a more solid structure than is actually required, which causes an increase
in the manufacturing cost.
SUMMARY OF THE INVENTION
[0004] In light of the above circumstances, an object of the present invention is to provide
a door structure for a vehicle, which requires no excessive load to be applied to
the lock release switch when the door is opened, so that an excessively solid switch
structure is unnecessary, and the manufacturing cost can be decreased.
[0005] Therefore, the present invention provides a door structure of a vehicle, comprising:
a door frame panel (e.g., a door frame panel 4 in an embodiment explained later);
an exterior member (e.g., a light housing 5 and a lower garnish 11 in the embodiment)
attached to a side of the door frame panel, said side facing the outside of the vehicle;
a lock release switch (e.g., a lock release switch 19 in the embodiment), provided
between the door frame panel and the exterior member (5), for releasing a door lock
state by an operation using a finger; and
a handle cover which is arranged around the lock release switch and has a recessed
portion (e.g., a recessed portion 21 in the embodiment) into which a hand is insertable
for opening the door, wherein:
the handle cover (e.g., a handle cover 18 in the embodiment) is coupled to the door
frame panel;
the lock release switch is coupled to the exterior member;
a through-hole (e.g., a through-hole 22 in the embodiment) is formed in the handle
cover; and
an operation device (e.g., an operation lever 23 in the embodiment) for operating
the lock release switch protrudes through the through-hole into the inside of the
recessed portion of the handle cover.
[0006] In accordance with the above structure, in order to release the locked door state
and to open the door, fingers are inserted into the recessed portion of the handle
cover, and the operation device for the lock release switch is operated so as to release
the locked door state. After the locked door state is released via the lock release
switch, the load accompanied with the opening of the door is mainly supported at the
recessed portion of the handle cover, and the load applied to the handle cover can
be supported by the door frame panel. In addition, the load applied to the lock release
switch when the locked door state is released is mainly supported by the exterior
member. Therefore, it is possible to prevent an excessive load from being exerted
on the lock release switch, and the lock release switch does not need to have a more
solid structure than is actually required, thereby reducing the manufacturing cost.
[0007] In a preferable example, the handle cover has a fittable device (e.g., a fittable
flange 28 (specifically, a fittable hook 30 thereof) in the embodiment) engaged with
the exterior member.
[0008] In this case, a face of the handle cover can easily and accurately conform to a face
of the exterior by engaging the fittable device of the handle cover with the exterior
member. Therefore, it is possible to improve the accuracy for coupling these elements,
and they can be installed easily.
[0009] In another preferable example, a rib (e.g., a rib 35 in the embodiment) is provided
at a part of the handle cover, said part being close to the outside of the vehicle,
and the rib protrudes toward a face of the exterior member, said face facing the interior
of the vehicle.
[0010] In this case, when an impact load is applied to the exterior member on the outside
of the vehicle, the load for moving the entire handle cover toward the interior of
the vehicle is exerted on the entire handle cover via the rib. Therefore, it is possible
to prevent the handle cover from inclining due to the load application in an inclined
direction, and thus interference between the inclined handle cover and the lock release
can be prevented.
[0011] In another preferable example, the through-hole of the handle cover is formed in
a manner such that the distance between the operation device for the lock release
switch and an edge of the through-hole toward the door frame panel is larger than
the distance between the operation device and another edge of the through-hole toward
the exterior member.
[0012] In this case, even when the lock release switch is relatively displaced toward the
interior of the vehicle with respect to the handle cover, due to the application of
an impact load from the outside of the vehicle, the operation device for operating
the lock release switch does not contact an edge (toward the door frame panel) of
the through-hole. That is, it is possible to reliably prevent such a contact with
the edge of the through-hole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013]
Fig. 1 is a perspective view of a vehicle to which the door structure of the present
invention is applied, and which is viewed from the back side thereof.
Fig. 2 is an enlarged sectional view along line A-A in Fig. 1.
Fig. 3 is a perspective view observed along the arrow B in Fig. 2.
Fig. 4 is a perspective view observed along the arrow C in Fig. 2.
Fig. 5 is a perspective view observed along the arrow D in Fig. 2.
Fig. 6 is an enlarged sectional view along line E-E in Fig. 4.
Fig. 7 is a diagram including part (A) which is a general sectional view of the door
corresponding to Fig. 2 before an impact is applied to the door, and part (B) which
is a general sectional view of the door corresponding to Fig. 2 while the impact is
applied.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Hereinafter, an embodiment in accordance with the present invention will be described
with reference to the appended figures.
[0015] Fig. 1 is a perspective view of a vehicle 1 to which the door structure of the present
invention is applied, and which is viewed from the back side thereof.
[0016] The rear side of this vehicle 1 has a door opening 2, and a tail gate 3 (i.e., a
door) is attached to the upper side of the door opening 2 via hinge brackets (not
shown) in a vertically openable and closeable manner. A door lock mechanism (not shown)
is provided between the lower-inner edge of the door opening 2 and the lower end of
the tail gate 3.
[0017] Fig. 2 is an enlarged sectional view along line A-A in Fig. 1. In the tail gate 3,
reference numeral 4 indicates a door frame panel made of a steel plate. A door windowpane
9 and an extra window panel 10 are attached to the outside (i.e., toward the outside
of the vehicle) of the door frame panel 3, and a lower garnish 11 (as an exterior
member) made of resin is provided on the lower side of the extra window panel 10.
[0018] Rear lights 13a and 13b (i.e., right and left lights 13a and a center light 13b)
are attached to the lower garnish 11 along the width of the vehicle, and an attachment
base 15 for attaching a license plate is provided below the rear light 13b which is
provided at the substantial center along the width of the vehicle. The door frame
panel 4 has an inner panel and an outer panel which are combined with each other by
hemming processing (a detailed structure thereof is not shown).
[0019] Fig. 3 is a perspective view observed along the arrow B in Fig. 2. As shown in Figs.
2 and 3, the center rear light 13b has a light housing 5 (as an exterior member) made
of resin, to which a lighting unit including translucent panels 6 and 7 is attached.
A step portion 8 (as a lower part of the light housing 5) is formed between the translucent
panel 6 (arranged at the back face of the vehicle body) and the back face (toward
the back of the vehicle body) of the lower garnish 11 which is positioned under the
translucent panel 6. On the bottom-face side (toward the interior of the vehicle)
of the step portion 8 of the light housing 5, a door handle part 16 and license lamps
17 are arranged. The door handle part 16 is positioned at the substantial center along
the width of the vehicle, and the license lamps 17 are positioned on the right and
left sides of the door handle part 16.
[0020] The door handle part 16 has (i) a handle cover 18 which is arranged on the bottom-face
side of the step portion 8 in the light housing 5 and is held by an operator who operates
the door, and (ii) a lock release switch 19 for releasing the lock state of the door
lock mechanism using an electric motor (not shown).
[0021] The handle cover 18 is made of a resin material, and includes a base part 20 which
has a rectangular shape and is exposed to the outside from the bottom face of the
light housing 5. Inside the base part 20, a recessed portion 21 is formed, into which
a hand is inserted for opening the door. This recessed portion 21 is produced by extending
upward substantially vertically from the inner edge (toward the interior of the vehicle,
that is, the left side in Fig. 2) of the base part 20, and is smoothly curved from
the deepest part (of the recessed portion) to the outer edge (toward the outside of
the vehicle, that is, the right side in Fig. 2) of the base part 20. With respect
to the recessed portion 21, in the following explanation, the substantially vertically
extending part on the vehicle-interior side is called a "vertical raising face 21a",
the most recessed part is called a "deepest part 21b", and the part extending from
the deepest part 21b to the edge on the side toward the outside of the vehicle is
called a "gentle slope 21c".
[0022] In the above recessed portion 21 of the handle cover 18, a through-hole 22 having
a substantially rectangular shape is formed, and an operation lever 23 (i.e., an operation
device) of the lock release switch 19 can be operated through this through-hole 22.
This through-hole 22 is formed from a position close to the end of the vertical raising
face 21a (i.e., before the deepest part 21 b) to the substantial center of the gentle
slope 21 c.
[0023] A pair of boss parts 24 are provided on the back side of the vertical raising face
21a in the recessed portion 21, and the head of a bolt 25 is embedded in each boss
part 24. The handle cover 18 contacts the door frame panel 4 via the boss parts 24
through an opening 26 formed in the lower garnish 11, and a nut 27 is screwed onto
the head of each bolt 25 which passes through the door frame panel 4. That is, basically,
the handle cover 18 is fastened to the door frame panel 4 using the bolts 25 and the
nuts 27.
[0024] Fig. 4 is a perspective view observed along the arrow C in Fig. 2, and Fig. 5 is
a perspective view observed along the arrow D in Fig. 2. Fig. 6 is an enlarged sectional
view along line E-E in Fig. 4.
[0025] As shown in Figs. 3, 4, and 6, fittable flanges 28 extend from both sides of the
handle cover 18 along the width of the vehicle. Each fittable flange 28 protrudes
from a position slightly distant from the back side of the base part 20, and is engaged
with a reception flange 29 of the light housing 5. Each of the reception flanges 29
has a wedge-shaped section (see Fig. 6) in which its upper surface is inclined in
a manner such that the height of the upper surface gradually increases toward the
outside of the vehicle. Each of the fittable flanges 28 forms an angle in conformity
with the inclination of the upper surface in the corresponding reception flanges 29.
At the end of each fittable flange 28 toward the outside of the vehicle, a fittable
hook 30 protruding downward is formed, which is engaged with an edge 31 (toward the
outside of the vehicle) of the corresponding reception flange 29. The relative positions
of the handle cover 18 and the light housing 5 are accurately defined when both flanges
28 and 29 are engaged while the relevant fittable hook 30 contacts the corresponding
edge 31.
[0026] As shown in Figs. 2 and 5, a pair of ribs 35 are formed on the upper face of the
handle cover 18 (i.e., the back face of the gentle slope 21c), which extend toward
the back of the vehicle. These ribs 35 are arranged on both sides of the through-hole
22 of the handle cover 18 along the width of the vehicle. As shown in Fig. 2, an end
of each rib 35 reaches or approaches a face (toward the interior of the vehicle) of
a vertical wall 40 of the light housing 5.
[0027] The lock release switch 19 has a switch main body attached to the upper surface of
a support wall 32 (of the light housing 5) which is arranged substantially horizontally.
The operation lever 23 protrudes downward through an opening 33 formed in the support
wall 32, and it further protrudes through the through-hole 22 of the handle cover
18 toward the inside of the recessed portion 21. When the operation lever 23 is pulled
toward the back side of the vehicle by fingers inserted into the recessed portion
21 of the handle cover 18, the lock release switch 19 is turned on so as to permit
the opening of the tail gate 3.
[0028] In Fig. 5, the support wall 32 and the opening 33 are omitted from the drawing for
convenience.
[0029] As shown in Fig. 2, in the initial state (i.e., the off state) of the operation lever
23, the operation lever 23 and the through-hole 22 of the handle cover 18 have a positional
relationship such that a distance d
1 from an edge (toward the interior of the vehicle) of the through-hole 22 to the operation
lever 23 is larger than a distance d
2 from another edge (toward the outside of the vehicle) of the through-hole 22 to the
operation lever 23.
[0030] As described above, in the present door structure, (i) the handle cover 18 having
the recessed portion 21 for holding the door is coupled to the door frame panel 4,
(ii) the lock release switch 19 is coupled to the support wall 32 of the light housing
5 which is an exterior member, and (iii) the operation lever 23 of the lock release
switch 19 is arranged in the recessed portion 21 through the through-hole 22 of the
handle cover 18. Therefore, the load applied to the operation lever 23 so as to release
the locked door state is supported via the lock release switch 19 by the light housing
5, and additionally, the load, which is applied to the handle cover 18 for raising
the tail gate 3 after the lock is released, is supported by the door frame panel 4
via the handle cover 18. Therefore, in the present door structure, when raising the
tail gate 3, no large load is exerted on the lock release switch 19; thus, it does
not need to have a more solid structure than is actually required, thereby reducing
the manufacturing cost.
[0031] Also in the present door structure, the inclined fittable flanges 28, each having
the fittable hook 30 at the head thereof, extend from the handle cover 18, and this
handle cover 18 is coupled to the door frame panel 4 while the fittable flanges 28
are engaged with the corresponding reception flanges 25 of the light housing 5. Therefore,
it is possible to further improve the accuracy for coupling the handle cover 18 to
the exterior members such as the light housing 5, the translucent panel 7, and the
like, thereby resulting in an improvement in the quality of the tail gate 3.
[0032] When installing the handle cover 18, it is temporarily fastened to the light housing
5 by engaging the fittable flanges 29 of the handle cover 18 with the corresponding
reception flanges 29, and after that, the handle cover 18 is fully fastened to the
door frame panel 4 using the bolts 25 and nuts 27. Therefore, when employing the present
door structure, the installation operation can be easily and accurately performed.
[0033] Also in the door structure of the present embodiment, the pair of ribs 35 is provided
at the handle cover 18, which reaches the vertical wall 40 of the light housing 5.
Therefore, even when an impact load is applied from the back of the vehicle, a moment
is not easily produced in the handle cover 18. Accordingly, it is possible to prevent
the handle cover 18 from considerably inclining when an impact occurs, and thus to
prevent interference between the inclined handle cover 18 and the operation lever
23 of the lock release switch 19.
[0034] In Fig. 7, part (A) shows a general sectional view of the door corresponding to Fig.
2 before an impact is applied to the door, and part (B) shows a general sectional
view of the door corresponding to Fig. 2 while the impact is applied.
[0035] Below, deformation of the tail gate 3 and the force applied to the handle cover 18
when an impact load is applied will be explained with reference to Fig. 7.
[0036] As shown in the part (B) of Fig. 7, when an impact load F toward the front side is
applied to the rear light 13b, the entire light housing 5 which receives the impact
load F moves frontward. In this process, the door frame panel 4 except for its lower
edge 4a is pushed frontward by the light housing 5. Accordingly, the distance between
the lower edge 4a and the light housing 5 is decreased, and a force for rotating the
handle cover 18 is more applicable to the handle cover 18.
[0037] In the door structure of the present embodiment, an impact load is applied via the
ribs 35 in the gravitational direction of the handle cover 18 as described above;
thus, the handle cover 18 is less inclined.
[0038] Also in the door structure, the distance d
1 from an edge (toward the interior of the vehicle) of the through-hole 22 to the operation
lever 23 is larger than the distance d
2 from another edge (toward the outside of the vehicle) of the through-hole 22 to the
operation lever 23. Therefore, even when the handle cover 18 is slightly inclined
when an impact load is applied, it is possible to reliably prevent interference between
the edge of the through-hole 22 and the operation lever 23.
[0039] While preferred embodiments of the invention have been described and illustrated
above, it should be understood that these are exemplary of the invention and are not
to be considered as limiting. Additions, omissions, substitutions, and other modifications
can be made without departing from the scope of the present invention. Accordingly,
the invention is not to be considered as being limited by the foregoing description,
and is only limited by the scope of the appended claims.
[0040] For example, in the above embodiment, the present invention is applied to a tail
gate which can be opened vertically; however, it can also be applied to a tail gate
which can be opened horizontally.