The present invention relates generally to a vehicle pedal assembly and, more specifically, to a mounting insert for an accelerator pedal assembly.
Accelerator pedal assemblies include pedal housings with mounting flanges that incorporate metal inserts adapted to receive screws or bolts that mount the pedal assembly to a vehicle mounting bracket which, in turn, mounts the pedal assembly to the floor of a vehicle.
The present invention is directed to a pedal assembly with an improved and lower cost metal mounting insert.
SUMMARY OF THE INVENTION
The present invention is generally directed to a vehicle pedal assembly comprising a housing for a pedal made of a molded plastic material, the housing including a mounting flange with a nut type mounting insert that has been insert molded into the plastic material of the mounting flange.
In one embodiment, the mounting insert is a T-nut type mounting insert including an interiorly threaded elongate sleeve and a radial collar with a plurality of tabs.
In one embodiment, the plurality of tabs depend downwardly from the radial collar in a relationship spaced and generally parallel to the sleeve and the longitudinal axis of the mounting insert and terminate in a rounded distal barb.
In one embodiment, the plurality of tabs depend downwardly from the radial collar in a relationship spaced and generally parallel to the sleeve and the longitudinal axis of the mounting insert and terminate in an arrow-shaped distal barb.
In one embodiment, the mounting insert is a slotted flange type nut wherein the radial collar includes a plurality of tabs and slots extending around the sleeve of the mounting insert in an alternating relationship.
In one embodiment, the mounting insert is a hex nut type mounting insert wherein the sleeve of the mounting insert is in the form of an interiorly threaded hex nut including first and second interiorly threaded collars extending outwardly from the respective distal end faces of the hex nut.
The present invention is also directed to a vehicle pedal assembly comprising a pedal housing made of a molded plastic material and including a mounting flange with a mounting insert, the mounting insert including a threaded sleeve extending into the mounting flange and a radial collar on the sleeve with a plurality of elongate tabs extending into the mounting flange for securing the mounting insert to the mounting flange of the pedal housing.
In one embodiment, the mounting insert is insert molded into the plastic material of the mounting flange, the plurality of tabs extending downwardly from the collar in a relationship spaced and parallel to the sleeve and the longitudinal axis of the mounting insert and terminating in a rounded distal barb.
In one embodiment, the mounting flange of the pedal housing defines a through-hole, a recess surrounding the through-hole, and a plurality of slots surrounding and spaced from the through-hole and extending in a direction normal to the opposed exterior surfaces of the mounting flange, the sleeve and the collar and the plurality of tabs of the mounting insert being press-fitted into the respective through-hole and the recess and the plurality of slots respectively in the mounting flange of the pedal housing for securing the mounting insert in the mounting flange of the pedal housing.
In one embodiment, the plurality of tabs extend downwardly from the collar of the mounting insert in a relationship spaced and parallel to the sleeve and the longitudinal axis of the mounting insert and terminate in an arrow-shaped distal barb that is press-fitted into a slot defined in the mounting insert.
Other advantages and features of the present invention will be more readily apparent from the following detailed description of the preferred embodiments of the invention, the accompanying drawings, and the appended claims.
These and other features of the invention can best be understood by the following description of the accompanying FIGURES:
The vehicle pedal assembly 10 is comprised of a pedal housing 12 that includes a plurality, and in the embodiment shown a pair, of outwardly protruding and extending mounting flanges or arms 14. An elongate pedal 13 (
The T-nut type mounting insert 70 (
A mounting screw or bolt 21 (
As shown in more detail in
A collar or flange or rim 76 extends radially outwardly from a top or distal peripheral edge of the exterior surface 75 of the base or sleeve 72 of the mounting insert 70. In the embodiment shown, the collar or flange or rim 76 extends around the full circumference of the exterior surface 75 of the base or sleeve 72 of the mounting insert 70 in a relationship and direction generally normal to the central longitudinal axis L of the mounting insert 70.
The collar or flange or rim 76 includes three elongate tabs or prongs 80 that project and extend unitarily generally normally downwardly from the outer peripheral edge of the collar 78. In the embodiment shown, each of the tabs 80 terminates in a rounded distal end or barb 82 including for example a radius of R 0.6 and the tabs 80 extend around the collar 78 in a spaced-apart and parallel relationship to each other, the exterior surface 75 of the sleeve 72 of the mounting insert 70, and the longitudinal axis L of the mounting insert 70. In the embodiment shown, the tabs 80 are spaced at one hundred twenty degree (120°) intervals and extend a length from the collar 76 which is approximately between one third (⅓) and one half (½) the length of the sleeve 72.
In the embodiment shown, each of the tabs or prongs 80 includes a generally straight elongate interior or inner side surface 83 that extends in a relationship parallel and spaced from the longitudinal axis L of the mounting insert 70, in a relationship opposed and spaced from the exterior surface 75 of the base or sleeve 72, and terminates in the interior or inner edge of the rounded distal end or barb 82. Each of the tabs or prongs 80 also includes an elongate exterior or outer side surface 85 that is spaced from and opposed to the interior side surface 83, curves inwardly from the collar 78 in the direction of the base or sleeve 72, and terminates in the exterior or outer edge of the rounded distal end or barb 82.
In the embodiment shown, each of the tabs or prongs 80 is comprised of a peripheral portion or region of the collar 78 which has been cut away from the collar 78 and subsequently bent down and away from the collar 78 and into an orientation and relationship generally normal to the collar 78 and generally parallel to and spaced and opposite from the exterior surface 75 of the sleeve 72 and the longitudinal axis L of the mounting insert 70. Moreover, in the embodiment shown, each of the tabs or prongs 80 is oriented relative to the sleeve 72 and the collar 76 in a relationship wherein the vertical plane of the tabs or prongs 80 extend through the longitudinal axis L of the mounting insert 70. Further, in the embodiment shown, the collar 76 when viewed from the planar perspective of
Each of the mounting inserts 70 is, during the process of molding the pedal housing 12, insert molded into the plastic material that comprises and forms each of the respective mounting flanges 14 of the pedal housing 12 into a position and relationship in each of the respective mounting flanges 14 as shown in
In the embodiment shown, the mounting insert 70 is insert molded into the plastic material of the mounting flange 14 in a relationship and orientation wherein the distal radial end of the sleeve 72 without the collar 76 is located opposite and abutting against the exterior surface of the vehicle pedal assembly mounting bracket 23 and further in a relationship wherein the tabs or prongs 80 of the mounting insert 70 extend in the direction of, and in a relationship generally normal to, the pedal assembly mounting bracket 23.
The respective pedal assembly mounting screws 21 are inserted successively through respective through-holes 27 (
In accordance with the present invention, the use of a mounting insert 70 including tabs or prongs 80 with rounded distal ends advantageously reduces stress concentrations in the encapsulating plastic material that surrounds the mounting insert 70 and forms the mounting flange 14, By reducing the stress concentrations, there is a lower likelihood of the plastic material cracking at extreme temperature conditions and also a corresponding increase and improvement in the torsional and axial retention characteristics of the mounting insert 70 in the mounting flange 14.
The pedal assembly housing 112 is identical in structure to the pedal assembly housing 12 with the exception of the structure of the mounting flanges 114 and the mounting inserts 170 and is adapted to be mounted and secured to the pedal assembly mounting bracket 23 in the same manner as the pedal assembly housing 12 and thus the earlier description of the elements of the pedal assembly housing 12, the pedal assembly 10, and the mounting bracket 23 is incorporated herein by reference with respect to the pedal assembly housing 112.
In the embodiment of the pedal housing 112 as shown in
Each of the mounting flanges 114 additionally includes a recessed surface 119 which is parallel and spaced from the exterior surface 131 of the flange 114 and defines a generally circular recess in the exterior upper surface 131 of the flange 114. In the embodiment shown, the one of the openings defined by the through-hole 115 terminates in the recessed surface 119.
A plurality of slots 123 are defined in and extend from the recessed upper surface 119 into the body of the mounting flange 114 in a relationship and orientation generally normal to the exterior opposed upper and lower surfaces 131 and 133 of the mounting flange 114, in the embodiment shown, three slots 123 extend circumferentially around the openings defined by the through-hole 115 at one hundred twenty degree (120°) intervals in a spaced-apart and generally parallel relationship relative to each other and the through-hole 115.
As shown in more detail in
A collar or flange or rim 176 extends radially outwardly from a top or distal peripheral edge of the exterior surface 175 of the sleeve 172 of the mounting insert 170. In the embodiment shown, the collar or flange or rim 176 extends circumferentially around the distal peripheral edge of the exterior surface 175 of the base or sleeve 172.
In the embodiment shown, the collar 176 includes three elongate tabs or prongs 180 that project and extend unitarily generally normally downwardly from a peripheral exterior distal edge of the collar 176. In the embodiment shown, each of the tabs or prongs 180 terminates in a downwardly pointing arrow-shaped distal end or barb 182 and the tabs 180 extend around the collar 178 in a spaced-apart and parallel relationship to each other, the exterior surface 175 of the sleeve 172 of the mounting insert 170, and the longitudinal axis L of the mounting insert 170. In the embodiment shown, the tabs 180 are spaced at one hundred twenty degree (120°) intervals from each other and have a length of approximately one half (½) the length of the sleeve 172.
Moreover, in the embodiment shown, the proximal end of each of the tabs or prongs 180 unitary with the peripheral edge of the collar 178 extends between a pair of slits or slots 181 defined in and extending from the peripheral exterior edge of the collar 178 and into the body of the collar 178.
Moreover, the arrow-shaped distal end or barb 182 on each of the tabs or prongs 180 includes a pair of distal and diametrically opposed exterior sloped camming surfaces 183 and 185 and a pair of opposed and diametrically opposed horizontal and flat shoulders 187 and 189.
As shown in
In accordance with the present invention, the exterior sloped camming surfaces 183 and 185 defined on the distal barb 182 of each of the tabs or prongs 180 are designed to guide the respective tabs or prongs 180 into and through the respective slots 123 when the respective mounting inserts 170 are press-fitted into the respective mounting flanges 114 and the exterior shoulders 187 and 189 defined on the distal barb 182 of each of the tabs or prongs 180 are designed to be surrounded by the plastic material of the respective mounting flanges 114 and prevent the respective mounting inserts 170 from being pulled out of or from coming out of the respective mounting flanges 114 after the respective mounting inserts 170 have been press-fitted into the respective mounting flanges 114.
In the embodiment shown, the tabs 180 are oriented relative to the sleeve 172 and the collar 176 of the mounting insert 170 in a relationship wherein the vertical plane of the tabs 180 is spaced and generally parallel to the longitudinal axis L of the sleeve 172 of the mounting insert 170.
Alternatively, each of the mounting inserts 170, like the mounting inserts 70, may be insert molded into the plastic material forming each of the respective mounting flanges 114.
The pedal assembly housing 212 is identical in structure to the pedal assembly housing 12 with the exception of the structure of the mounting inserts 270 and is adapted to be mounted and secured to the pedal assembly mounting bracket 23 in the same manner as the pedal assembly housing 12 and thus the earlier description of the elements of the pedal assembly housing 12, the pedal assembly 10, and the mounting bracket 23 is incorporated herein by reference with respect to the pedal assembly housing 212.
Specifically, the pedal assembly housing 212 comprises a housing for the pedal 13 and includes a plurality of outwardly protruding mounting flanges or arms 214. The mounting insert 270 is located and secured in each of the flanges 214 in the same manner as described above with respect to the mounting insert 70 and thus incorporated herein by reference including specifically and as by, for example, insert molding during the forming and manufacturing process into the plastic material forming and defining each of the mounting flanges 214.
As shown in more detail in
A collar or flange or rim 276 extends radially outwardly from a top peripheral distal edge of the exterior surface 275 of the base or sleeve 272 of the mounting insert 270. In the embodiment shown, the collar or flange or rim 276 extends around the full circumference of the exterior surface 275 of the base or sleeve 272 of the mounting insert 270 and extends in a direction generally normal to the central longitudinal axis L of the mounting insert 270.
The collar or flange 276 includes a plurality of tabs 280 that project and extend unitarily generally outwardly from the collar 276 and are defined by a plurality of slits or slots 281 defined in the collar or flange 276. In the embodiment shown, the tabs 280 and slots 281 extend on the collar 276 and around the circumference of the top peripheral distal edge of the exterior surface 275 of the base or sleeve 272 in an alternating and spaced apart relationship and direction generally normal to the longitudinal axis L of the mounting insert 270.
Moreover, in the embodiment shown, each of the tabs 280 projects and slopes both outwardly and downwardly away from the exterior surface 275 of the base or sleeve 272 and the collar 276 of the mounting insert 270 and each of the slits or slots 281 defined in the collar or flange 276 is generally V-shaped.
Each of the mounting inserts 270 is insert molded into the plastic material of each of the respective mounting flanges 214 of the pedal housing 212 into a position and relationship in each of the respective mounting flanges 214 as shown in
In the embodiment shown, the mounting insert 270 is insert molded into the plastic material of the mounting flange 214 in a relationship and orientation wherein the radial end face of the base or sleeve 282 without the collar 276 is located opposed and abutting against the exterior surface of the vehicle pedal assembly mounting bracket 23 when the pedal assembly housing 212 is mounted and secured to the mounting bracket 23.
The mounting screws 21 are threaded successively into respective through-holes 27 (
The pedal assembly housing 112 is identical in structure to the pedal assembly housing 12 with the exception of the structure of the mounting inserts 370 and is adapted to be mounted and secured to the pedal assembly mounting bracket 23 in the same manner as the pedal assembly housing 12 and thus the earlier description of the elements of the pedal assembly housing 12, the pedal assembly 10, and the mounting bracket 23 is incorporated herein by reference with respect to the pedal assembly housing 112.
Specifically, the pedal assembly housing 312 comprises a housing for the pedal 13 and includes a plurality of outwardly protruding mounting flanges or arms 314. The mounting insert 370 is located and secured in each of the mounting flanges 314 in the same manner as described above with respect to the mounting insert 70, the description of which is thus incorporated herein by reference and specifically as by, for example, insert molding into the plastic material defining each of the mounting flanges 314 during the molding operation that is used during the manufacturing operation to form the pedal assembly housing 312 and more specifically the respective mounting flanges 314 of the pedal assembly housing 312.
As shown in more detail in
A pair of generally cylindrically shaped central and interiorly threaded collars 377 and 379 protrude unitarily outwardly from the respective radial distal end faces of the nut 371 and extend in a relationship generally parallel and spaced from the longitudinal axis L of the nut 371. The collar 377 surrounds the opening defined in the one end of the nut 371 and the collar 379 surrounds the opening defined in the opposite end of the nut 371.
Each of the mounting inserts 370 is insert molded into the plastic material of each of the respective mounting flanges 314 of the pedal housing 312 into a position and relationship in each of the respective mounting flanges 314 as shown in
The mounting screws 21 are threaded successively into respective through-holes 27 (
Numerous variations and modifications of the embodiments described above may be effected without departing from the spirit and scope of the novel features of the invention. It is to be understood that no limitations with respect to the pedal assembly and mounting inserts illustrated herein are intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.
This application claims the benefit of the filing date and disclosure of U.S. Provisional Patent Application Ser. No. 61/806,068 filed on Mar. 28, 2013, the contents of which are entirely incorporated herein by reference as well as all references cited therein.
Number | Date | Country | |
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61806068 | Mar 2013 | US |