BACKGROUND
The present invention is directed to regulator systems that employ cables to move components, such as in a vehicle to open and close a window, a sunroof, a power sliding door, a power lift gate, etc., or make seat adjustments, activate handicap ramps, or the like.
By way of example, regulators that utilize a cable drive mechanism (e.g., rail or rail-less regulators) typically employ cables for moving windows, doors, ramps, etc. to various positions within a system. The cable is attached to the item or object to be moved, such as to the window and/or a window lift plate (a plate that connects the lift mechanics to an edge, usually the bottom edge, of the window) and is guided by pulleys, conduits, channels, and other types of guide mechanisms to a driving source, such as an actuator drum or the like.
Maintaining tension in the cable is important for effective operation of the regulator system. A loose cable can result in an inoperable regulator, especially if the cable or a portion of the cable separates from the guide mechanics. Typically, springs in combination with pulleys and/or guide blocks, are used to maintain the desired tensioning force on the cable. However, the use of springs, guide blocks and pulleys in regulator systems increases the costs and complexities of manufacturing and/or repairing the systems.
Therefore, there is a need in the art for a mechanism for maintaining tension in the cable of a regulator system that reduces the costs and complexities of manufacture and repair of the system.
SUMMARY OF THE INVENTION
One or more embodiments of the present invention provide a regulator system that employs a tensioning source to maintain desired tension of a cable while reducing the parts count and complexity (e.g., by eliminating one or more springs and/or pulleys), reducing costs, and providing design flexibility for pulley clearances, item travel (e.g., window pane travel), Bowden-less cable systems, or the like.
In accordance with at least one aspect of the present invention, systems are disclosed for employing one or more cable guide tensioners, such as with at least a window lift plate in a vehicle or the like, for opening and closing a window in response to an actuator or driving source.
In accordance with one or more embodiments of the present invention, a cable guide tensioner includes: first and second spaced apart opposing surfaces, and a peripheral surface extending between the first and second surfaces. The tensioner operates to: slidingly engage the cable over a length of the peripheral surface extending between an entry point and exit point; and vary at least one of the length and a straight-line distance between the entry point and exit point as a function of rotation about a pivotal axis, the pivotal axis extending transverse to the first and second surfaces.
The cable guide tensioner is operable to provide a spring force to the cable such that the spring force is biased to rotate the cable guide tensioner and expand a distance of cable travel, and induce tension in the cable. Through a series of rotational orientations, the cable guide tensioner rotates from a starting ‘rest position’ orientation, where the tensioner has not yet been activated or engaged to expand a distance of cable travel, to one of a series of engaged ‘activated position’ orientations, which serve to expand the distance of cable travel so that any cable slack (resulting in a lowered cable tension) is compensated for by the increase in distance. In this manner the cable tension of the regulator system is maintained at a selected cable tension.
The cable guide tensioner may be operable to rotate through a series of orientations from a resting position orientation to an activated position orientation as the cable stretches such that tension is maintained sufficiently high within the cable. For example, the cable guide tensioner may be operable to attain the first activated position orientation when the tension in the cable falls below a selected threshold tension. The spring force of cable guide tensioner may be biased toward the activated position orientation, thereby applying the spring forces to the cable and tending to expand the distance of cable travel, and induce tension in the cable.
Alternatively or additionally, the cable guide tensioner is operable to rotate through a series of orientations in only one direction by a ratchet mechanism, each orientation representing one sliding movement of a complementary plurality of ratchet teeth. The ratchet teeth are orientated to allow movement of the cable guide tensioner in only one direction so that the distance of cable travel, and thus cable tension, will increase.
Alternatively or additionally, the cable guide tensioner is operable to rotate through a series of orientations preferably in one direction to increase the distance of cable travel, and thus cable tension. However, if the cable tension is overcompensated for by the rotation of the cable guide tensioner, a second spring force of the cable guide tensioner biased toward the resting position would disengage the unidirectional ratchet teeth by a release latch and rotate the cable guide tensioner back one or more orientations to reduce the cable tension.
Other aspects, features, advantages, etc. will become apparent to one skilled in the art when the description of the invention herein is taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purposes of illustration, there are forms shown in the drawings that are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a schematic view of a cable regulator system employing a cable guide tensioner in accordance with at least one aspect of the present invention.
FIG. 2 is a perspective view of a cable guide tensioner in accordance with at least one embodiment of the present invention.
FIG. 3 is a cross-sectional view taken through line 3-3 of the cable guide tensioner of FIG. 2.
FIG. 4 is a side view of the cable guide tensioner of FIG. 2 in accordance with at least one aspect of the present invention where the tensioner is in the resting position having the shortest available length and distance between the entry point and exit point of the cable.
FIG. 5 is a side view of the cable guide tensioner of FIG. 2 in accordance with at least one aspect of the present invention where the tensioner is in an activated position in which the tensioner has rotated and increased the length and distance between the entry point and exit point of the cable in response to cable slack.
FIG. 6 is a side view of the base structure in accordance with at least one embodiment of the present invention.
FIG. 7 is a cross-sectional view taken through line 7-7 of the base structure of FIG. 6 in accordance with at least one embodiment of the present invention.
FIG. 8 is a peripheral view of the cable guide tensioner of FIG. 2 connected to the base structure of FIG. 6.
FIG. 9 is a cross-sectional view of the cable guide tensioner of FIG. 2 connected to the base structure of FIG. 6.
FIG. 10 is a perspective view of a cable guide tensioner in accordance with at least one embodiment of the present invention.
FIG. 11 is a side view of the base structure in accordance with at least one embodiment of the present invention.
FIG. 12 is a peripheral view of the cable guide tensioner of FIG. 10 connected to the base structure of FIG. 11.
FIG. 13 is a cross-sectional view of the cable guide tensioner taken through line 3-3 of the cable guide tensioner of FIG. 2.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
For the purposes of describing various aspects of the present invention, reference may be made to using a cable guide tensioner in a window regulator system of a vehicle. Indeed, embodiments of the invention have specific utility in the window regulator context. It will be appreciated by those skilled in the art, however, that the various embodiments of the cable guide tensioner described and claimed herein may have application to many other areas, including movement of a window, a sunroof, a sliding door, a lift gate, a lift platform (such as for a handicap ramp), one or more portions of a seat (such as the seat back, seat base, forward/rearward position, etc.), or the like. In the case of window regulator systems, the embodiments of the present invention have applicability for use in operating windows of a vehicle, such as a car, truck, van, boat, motor vehicle, or the like.
In particular, the cable guide tensioner of the present invention is directed to guide a cable in the system, apply tension in the cable, and maintain the tension (at least to a degree) as the cable stretches over its life.
FIG. 1 is a schematic view of a cable guide regulator system 100 in accordance with at least one aspect of the present invention. The cable guide regulator system 100 may be for a vehicle window (and may be referred to as such) or any of the aforementioned other applications. The cable guide regulator system 100 is operable to move an object (generally designated 10) and includes at least one cable guide tensioner 102, a base structure, a cable 106, a driving source 108, and another cable guide element 110. The cable 106 may have springs 14 (such as a coil spring) at the ends of the cable 106.
As discussed above, the object 10 may take on any number of forms, such as for a window of a vehicle. In such an example, the object 10 may include a window lift plate coupled to a bottom edge of a window panel. Respective ends of the cable 106 originate at, and are coupled to, the object 10 and traverse the cable guide tensioner 102, the driving source 108, and the cable guide element 110. The driving source 108 engages the cable 106 such that it is operable to actuate and move the cable 106 around the cable guide element 110 and cable guide tensioner 102, thereby moving the object 10 down or up (in the example of FIG. 1) or in other directions depending on the application. Those skilled in the art will recognize that any type of driving source 108 may be used to actuate and/or drive the cable 106, such as an actuator drum or the like, either motorized or manual.
In some embodiments, such as in a window regulator system, the cable guide regulator system 100 may include a base to couple the cable guide tensioner 102 to a carrier module of a vehicle door. The base may be part of, or integrated to, the carrier module, the carrier module being a regulator rail, sheet metal inner or other component known to a skilled artisan. A guide rail 12 may be coupled to the carrier module to provide a guide for the object (e.g., the window lift plate and window) along a predetermined path or direction as shown by the arrows.
In accordance with one or more aspects of the present invention, the cable guide tensioner 102 is operable to impart tension to the cable 106. As will be discussed in more detail later in this description, this is accomplished by providing a spring functionality at the cable guide tensioner 102, which engages the base such that the cable guide tensioner 102 tends to be biased to expand the length and/or axis between the entry point and exit point of the cable 106, and induce tension in, the cable 106. This eliminates the need for a separate springs 14 (such as a coil spring) at the end of the cable 106.
In one or more embodiments, the cable guide element 110 may be a conventional pulley, in which case a spring 14 may be employed at the end of the cable 106 at the bottom of the object 10. Preferably, however, the cable guide element 110 is also a cable guide tensioner 102, in which case no pulleys and/or coil springs need remain in the system 100 to provide tension to the cable 106. Elimination of springs 14 and/or pulleys from the system 100 increases the packaging area in the area of the object 10 (such as the window lift plate), thereby permitting any mechanisms for coupling the cable 106 to the object 10 to be of a reduced size. Elimination of parts also reduces manufacturing and repair costs and/or complexities.
Reference is now made to FIG. 2, which is a perspective view of the cable guide tensioner 102. The cable guide tensioner 102 includes a first opposing surface 200 and a second opposing surface 202. The perimeters of the two opposing surfaces 200, 202 are shaped so that the surfaces are in the form of a circle, oblong shape, curvilinear shape, ellipse or an oval. As shown in the embodiment of FIG. 2, the perimeters of the two opposing surfaces 200, 202 form an oval. The cable guide tensioner 102 includes a peripheral surface 204 between the two opposing surfaces 200, 202. The first opposing surface 200 and the second opposing surface 202 extend transversely beyond the peripheral surface 204 and form a first and second channel wall 206 and 208. The peripheral surface 204 and the first and second channel walls 206 and 208 form a channel operable to permit the cable 106 to slide therein and to change the direction of travel of the cable 106 (e.g., change the direction by about 180 degrees) The walls 206 and 208 are sized and shaped to guide and maintain the cable 106 in the channel, without permitting the cable 106 to slip off the peripheral surface 204. A pivotal axis, Pi, is defined as extending transversely through a pivotal axis aperture 210 situated through the first opposing surface 200 and second opposing surface 202 of the cable guide tensioner 102.
The cable guide tensioner 102 includes a connecting mechanism 112 that connects the cable guide tensioner 102 to a stationary surface and functions to allow movement (e.g., rotation) of the cable guide tensioner 102 in one direction. The connecting mechanism 112 may be in the form of a ratchet-type system. A shaft 212, having a widened end cap, is situated in the aperture 210 so that the shaft 212 is transverse to the opposing surfaces 200 and 202 and that one end of the shaft 212 extends through the opposing surfaces 200 and 202 to permit the cable guide tensioner 102 to rotate about the shaft 212. The cable guide tensioner 102 includes a spring 214 having two ends, situated around the pivotal axis aperture 210. One end of the spring 214 is disposed on opposing surface 200 at the spring attachment aperture 216, and the other end of the spring 214 is attached to a base (as shown in FIG. 6). The spring 214 may also be situated around the connecting mechanism 112 (not shown). The spring 214 functions to provide a spring force to rotationally bias the cable guide tensioner 102 and expand a distance of cable travel, and induce tension in the cable 106.
Reference is now made to FIG. 3, which illustrates a cross-sectional view taken through line 3-3 of FIG. 2. Disposed on the opposing surface 200 encircling the spring 214 is a first plurality of ratchet teeth 218. As shown, the pivotal axis aperture 210 is situated transversely to the opposing surfaces 200 and 202. The orientation of the pivotal axis aperture 210 relative to the spring attachment aperture 216 and the first plurality of ratchet teeth 218 is shown. Also evidenced by this cross-sectional view is the location of the pivotal axis aperture 210 such that it is located off-center from the cable guide tensioner 102 and functions to permit the rotation of the cable guide tensioner 102 in a manner to expand or contract the distance of cable travel.
As best seen in FIG. 4, the cable guide tensioner 102 is in the resting position orientation. The resting position orientation is defined as an orientation at which the cable guide tensioner 102 does not substantially expand (or minimizes) the distance of cable travel. The resting position orientation may be when the spring 214 is in the most wound position. The peripheral surface 204 includes an entry point 220, which is defined as the point where the cable 106 first makes contact with the peripheral surface 204. The peripheral surface 204 further includes an exit point 222, which is defined as the point where the cable 106 last makes contact with the peripheral surface 204. The entry and exit points 220 and 222 change position along the peripheral surface 204 depending on the rotational orientation of the cable guide tensioner 102 relative to the base (as shown in FIG. 6) A path length, L, is defined as the length measured along the peripheral surface 204 between the entry point 220 and the exit point 222. A distance, D, is defined as the shortest, straight-line, distance between the entry point 220 and the exit point 222. The L and D measurements vary as the cable guide tensioner 102 moves from the resting position orientation to one of a series of activated position orientations. The activated position orientation is defined as any of a series of rotational orientations of the cable guide tensioner 102 about the pivotal axis, Pi, resulting from a need to increase cable tension. This expands the distance of cable travel and compensates for cable slack. It is a preferred function of the cable guide tensioner 102 that both L and D measurements are the greatest at the maximal activated position orientation.
As shown in FIG. 5, the cable guide tensioner 102 is positioned at one rotational orientation of the activated position. The activated position results when the cable guide tensioner 102 rotates in response to a slackening of the cable tension, and thus L and D are increased. The increased L and D distances are directly related to a selected tension level (or within a preferred range) that permits the cable guide regulator system 100 to function properly.
Reference is now made to FIG. 6, which is a side view of the base 114. The base 114 includes a surface 300 which may be part of, or integrated to, the carrier module of the vehicle door panel and functions as a stationary surface to which the cable guide tensioner 102 may be engaged. The carrier module may be a regulator rail, sheet metal inner or other component known to a skilled artisan. The base 114 further includes an aperture 302 disposed through the surface 300, that functions to receive the exposed end of the shaft 212 of the cable guide tensioner 102. The aperture 302 further includes threads 304 (as shown in FIG. 7) that function to receive the shaft 212 having complementary threads so that the shaft 212 is stationary in the base 114 and permits the cable guide tensioner 102 to rotate freely. The shaft 212 may also be in the form of a rivet or axle. The base 114 further includes a connecting mechanism 112 that connects the base 114 to the cable guide tensioner 102 and functions to allow movement (e.g., rotation) of the cable guide tensioner 102 in one direction relative to the base 114. The connecting mechanism 112 may be in the form of a ratchet-type system. A complementary spring attachment aperture 306 disposed in, or through, the surface 300, functions to receive one end of the spring 214. Disposed on the surface 300, encircling the aperture 302 and complementary spring attachment aperture 306, is a second plurality of ratchet teeth 308. The second plurality of teeth 308 are complementary to the first plurality of teeth 218 (as depicted in FIG. 2) so that they contact each other and function to permit the rotation of the cable guide tensioner 102 about the pivotal axis Pi in only one direction. Thus, the cable guide tensioner 102 comes to rest at any of a series of orientations. As the teeth of the first plurality 218 slide over the teeth of the second plurality 308, the cable guide tensioner 102 rotates to the next ‘active position’ orientation. Each orientation differs from the next orientation by the granularity determined by the respective sizes and configuration of the teeth.
FIG. 7 represents a cross-sectional view taken through line 7-7 of FIG. 6. The orientation of the aperture 302 relative to the complementary spring attachment aperture 306 and the second plurality of ratchet teeth 308 is shown. The aperture 302 further includes threads 304 disposed on the interior surface of the aperture.
Reference is now made to FIGS. 8 and 9, where FIG. 8 is a peripheral view of the cable guide tensioner 102 disposed on the base 114 via the connecting mechanism 112, and FIG. 9 is a cross-sectional view illustrating the function and operation of the cable guide tensioner 102 to achieve the aforementioned spring forces against the cable 106. As shown, the cable guide tensioner 102 and base 114 engage one another by the first and second plurality of teeth 218 and 308. The smooth end of the shaft 212 slides through the pivotal axis aperture 210 of cable guide tensioner 102, and the threaded end of the shaft 212 is threaded onto the inner threads 304 of the aperture 302 on the base 114 until the widened end cap of the shaft 212 is snug against the opposing surface 202. According to one embodiment of the invention, the connecting mechanism 112 may further include a first compliance spring 310 coaxial with the shaft 212 and situated between the cable guide tensioner 102 and the base 114, and a second compliance spring 312 coaxial with the shaft 212 and situated between the widened end cap of the shaft 212 and the cable guide tensioner 102. The compliance springs 310, 312 function to provide a spring force to the cable guide tensioner 102 such that the spring force is biased to expand the distance between the cable guide tensioner 102 and the base 114 so as to permit the first and second plurality of teeth 218 and 308 to snugly engage one another yet provide a sufficient amount of give to allow the teeth to slide over one another.
Reference is now made to FIGS. 10 and 11, where FIG. 10 is a perspective view of an embodiment the cable guide tensioner 102 and FIG. 11 is a side view of the base structure 114. In addition to the features of the cable guide tensioner 102 as described for FIG. 2, excluding the spring 214 and the spring attachment aperture 216, the cable guide tensioner 102 includes a rod 400 disposed transversely on the first opposing surface 200. The base 114 includes a curved channel 402 along the surface 300 such that the curve is complementary to the curvature of the rotation of the cable guide tensioner 102 along the pivotal axis Pi. The location of the rod 400 on the first opposing surface 200 may be adapted to complement the location of the curved channel 402. The length of the rod 400 is adapted so that one end of the rod 400 extends through, and is received transversely into, the channel 402 and will not slip out. A spring 404 is situated within the channel 402 so that one end is adjacent to a channel wall while the other end is situated against the rod 400. FIG. 12 is a peripheral view of the cable guide tensioner 102 of FIG. 10 connected to the base structure and illustrates the orientation of the rod 400 in relation to the channel 402 and spring 404 of the base 114. The spring 404 functions to create a spring force to bias the cable guide tensioner 102 to rotate to the next ‘active position’ orientation.
FIG. 13 is a cross-sectional view of an embodiment of the cable guide tensioner 102. The cable guide tensioner 102, as described above, may further include at least one integrated spring finger 500 disposed on the opposing surface 200. The integrated spring fingers 500 function to provide a spring force to the cable guide tensioner 102 such that the distance between the cable guide tensioner 102 and the base 114 expands so as to permit the first and second plurality of teeth 218 and 308 to snugly engage one another yet provide a sufficient amount of give to allow the teeth to slide over one another. The amount of spring force may be optimized by adjusting the height of the integrated spring fingers 500. The integrated spring fingers 500 may or may not be used in conjunction with the first compliance spring 310 and second compliance spring 312. It is also understood that one or more integrated spring finger 500 may alternatively be disposed on the surface 300 of the base 114, or may be disposed on both the first opposing surface 200 and surface 300.
Thus, in accordance with one aspect of the present invention, the cable guide tensioner 102 provides a spring force to the cable 106 such that a distance of cable travel expands, and tension is induced in the cable. The cable guide tensioner 102 is operable to rotate through a plurality of orientations from a first resting position orientation to any one of a series of activated position orientations such that tension is maintained sufficiently high within the cable 106. In this regard, the length (L) between the entry point 220 and exit point 222 of the cable 106 varies as the cable guide tensioner 102 rotates through a plurality of orientations. Similarly, the distance D between entry and exit points 220 and 222 of the cable 106 entering and exiting the channel 200 also varies as the cable guide tensioner 102 rotates.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
Patent Application
20100258664
