This invention generally relates to solenoid actuators, and more particularly, solenoid actuators for use in powering mechanisms on motor vehicles.
Power-driven components are becoming commonplace in motor vehicles as customers demand comfort and convenience. Power-actuated door latches and locks, hood releases, trunk openers, fuel-door openers, and hatches, for example, are either standard or optional equipment on many of today's cars and trucks. Customers looking to enhance their existing, non-powered equipment commonly turn to aftermarket components for conversion to power-driven equipment.
The linear motion of the plunger 13 can be used to power other mechanisms that are normally manually operated from a first position to a second position. Examples of these other mechanisms include the opening/closing and locking/unlocking of door latches, hood releases, trunk openers, fuel-door openers, and hatches.
The solenoid actuator 2 coverts electrical energy to linear motion.
Known solenoid actuators 10 have a single eyelet 14 which are adapted to engage a hook on a lever, rather than adapted for use with a cable 30. This causes a number of significant problems in using solenoid actuators 10 for pulling a cable 30. One significant problem is that a single eyelet 14 does not provide the necessary adjustability for use as a cable-pulling device. This is particularly so when the solenoid actuator 10 is part of a conversion kit for hobbyist to install on their motor vehicles. A single eyelet 14 provides only a few choices for coupling the cable 30 to the plunger 13.
The crimping tab 32 is only as secure as the grip it has on the cable proximal end 31. The strong pull of the plunger 13 over many cycles puts much stress on the crimping tab 32 leading to eventual slippage and failure. Considering that the length of the cable 30 is unique and determined by the specific application, the crimping tab 32 is coupled to the cable proximal end 31 by the installer. Lack of skill in assembly will also contribute to premature failure of the crimping tab 32.
In application, the looped cable proximal end 31 is problematic over time. After a number of cycles, the loop 35 stretches and enlarges. This not only causes the cable 30 to slacken, but also interferes with proper function. An oversized loop 35 can shift in the eyelet 14.
It is desired in the art to have a solenoid actuator for use in pulling a cable that addresses the problems associated with currently-available solenoid actuators. It is desired to provide a solenoid actuator that allows for greater adjustability for coupling a cable to the plunger. Further, it is desired to provide a solenoid actuator that overcomes the problem of a cable loop becoming retrograde preventing operation of the attached mechanism. Further, there is a need for a solenoid actuator that is easy to install, regardless of the application. There is also a need to reduce specialization of solenoid actuators, providing more universal designs which results in lower costs per unit, greater flexibility in the number of applications, and improved economies of scale for the manufacturer.
A solenoid actuator is provided in an embodiment in accordance with the present invention, comprising a solenoid including a winding defining a bore, and a plunger including a plunger first end, a plunger second end opposite the plunger first end, and a plurality of through-holes defining eyelets disposed in the plunger second end, the plunger first end slidingly received within the bore and the plunger second end extending from the bore, the eyelets adapted to accept a cable therethrough. In another embodiment, the solenoid actuator includes eyelets that are substantially the same size, substantially equally spaced and substantially collinear. In another embodiment, the solenoid actuator includes eyelets that are in a staggered arrangement. In another embodiment, the plunger first end comprises a retention portion adapted to couple with a suitable coupler adapted to retain the plunger first end within the bore.
A plunger for use with a solenoid having a winding defining a bore is provided in an embodiment in accordance with the present invention, comprising a plunger first end, a plunger second end opposite the plunger first end, and a plurality of through-holes defining eyelets disposed in the plunger second end. The plunger first end is adapted to extend within the bore and the plunger second end adapted to extend from the bore. The eyelets are adapted to accept a cable therethrough. In another embodiment, the eyelets are substantially the same size, substantially equally spaced and substantially collinear. In another embodiment, the eyelets are in a staggered arrangement. In another embodiment, the plunger first end comprises a retention portion adapted to couple with a suitable coupler adapted to retain the plunger first end within a bore of a solenoid.
A power latching device is provided in an embodiment in accordance with the present invention, comprising a latch assembly, a cable having a cable proximal end and an opposite cable distal end, the cable proximal end coupled to the latch assembly at a cable proximal end, and a solenoid actuator comprising a solenoid including a winding defining a bore and a plunger including a plunger first end, a plunger second end opposite the plunger first end, and a plurality of through-holes defining eyelets disposed in the plunger second end. The plunger first end is disposed within the bore and the plunger second end extends from the bore. The eyelets are adapted to accept the cable distal end therethrough. The cable is coupled to the plunger. In another embodiment, the plunger first end comprises a retention portion adapted to couple with a suitable coupler adapted to retain the plunger first end within the bore.
An adapter for a solenoid plunger having a plunger eyelet is provided in an embodiment in accordance with the present invention, comprising a sleeve comprising a plurality of through-holes defining a plurality of sleeve eyelets. The sleeve having a cavity adapted to accept at least a portion of the plunger second end therein. The sleeve eyelets are adapted to align in cooperative alignment with the plunger eyelet. The sleeve eyelets are adapted to accept a cable therethrough. In another embodiment, the adapter further comprises a fastener adapted to couple the sleeve to the plunger.
An adapter for a solenoid plunger is provided in an embodiment in accordance with the present invention, comprising a sleeve comprising a plurality of through-holes defining a plurality of sleeve eyelets. The sleeve having a cavity that is adapted to accept at least a portion of the plunger therein. The sleeve eyelets are adapted to extend beyond the plunger and adapted to accept a cable therethrough. In another embodiment, the sleeve further comprises a fastener adapted to couple the sleeve to the plunger.
A method of using a solenoid actuator is provided in an embodiment in accordance with the present invention, comprising providing a solenoid actuator comprising a winding defining a bore and a plunger including a plunger first end, a plunger second end opposite the plunger first end, and a plurality of through-holes defining eyelets disposed in the plunger second end. The plunger first end is disposed within the bore and the plunger second end extending from the bore. The eyelets are adapted to accept a cable therethrough. The cable distal end of a cable is extended through at least one eyelet and the cable distal end is coupled to the plunger. In another embodiment, extending a cable distal end of a cable through at least one eyelet and coupling the cable distal end to the plunger comprises extending a cable distal end of a cable through one eyelet from a plunger first side through to a plunger second side opposite the plunger first side and coupling the cable distal end adjacent the plunger second side so as to prevent the cable distal end from disengaging the plunger. In another embodiment, extending a cable distal end of a cable through at least one eyelet and coupling the cable distal end to the plunger comprises extending a cable distal end of a cable through one eyelet from a plunger first side through to a plunger second side opposite the plunger first side and coupling a fastener on the cable distal end adjacent the plunger second side so as to prevent the cable distal end from disengaging the plunger.
In another embodiment, extending a cable distal end of a cable through at least one eyelet comprises extending a cable distal end of a cable through at least two eyelets. In another embodiment, extending a cable distal end of a cable through at least one eyelet comprises weaving a cable distal end of a cable through at least two eyelets. In another embodiment, extending a cable distal end of a cable through at least one eyelet and coupling the cable distal end to the plunger comprises extending a cable distal end of a cable through at least two eyelets and coupling a fastener on the cable distal end adjacent the plunger second side so as to prevent the cable distal end from disengaging the plunger.
In another embodiment, extending a cable distal end of a cable through at least one eyelet and coupling the cable distal end to the plunger comprises extending a cable distal end of a cable through at least two eyelets, forming the cable distal end into a loop that includes a portion of the cable distal end that is within the at least two eyelets, and coupling the cable distal end and a portion of the cable to secure the loop and prevent the cable distal end from disengaging the plunger. In another embodiment, extending a cable distal end of a cable through at least one eyelet and coupling the cable distal end to the plunger comprises extending a cable distal end of a cable through at least two eyelets, forming the cable distal end into a loop that includes a portion of the cable distal end that is within the at least two eyelets, and coupling a fastener on the cable distal end and a portion of the cable to secure the loop and prevent the cable distal end from disengaging the plunger.
A method of using a solenoid actuator is provided in an embodiment in accordance with the present invention, comprising providing a solenoid actuator comprising a winding defining a bore and a plunger including a plunger first end, a plunger second end opposite the plunger first end, and through-holes defining a plunger eyelet disposed in the plunger second end. The plunger first end is disposed within the bore and the plunger second end extends from the bore. A sleeve is provided comprising a plurality of through-holes defining a plurality of sleeve eyelets, the sleeve having a cavity adapted to accept at least a portion of the plunger second end therein, the sleeve eyelets are adapted to align in cooperative alignment with the plunger eyelet, the sleeve eyelets adapted to accept a cable therethrough. A cable distal end of a cable is extended through at least one sleeve eyelet and coupled to the sleeve.
A method of using a solenoid actuator is provided in an embodiment in accordance with the present invention, comprising providing a solenoid actuator comprising a winding defining a bore and a plunger including a plunger first end, a plunger second end opposite the plunger first end, the plunger first end disposed within the bore and the plunger second end extending from the bore. A sleeve is provided comprising a plurality of through-holes defining a plurality of sleeve eyelets, the sleeve having a cavity that is adapted to accept at least a portion of the plunger second end therein, the sleeve eyelets extending beyond the plunger second end and adapted to accept a cable therethrough. At least a portion of the plunger second end is disposed into the cavity and coupled to the plunger second end. A cable distal end of a cable is extended through at least one sleeve eyelet and coupled to the sleeve.
A power assembly for use in a vehicle having a lever, a lever head, a restoring spring, and a latching mechanism is provided in an embodiment in accordance with the present invention, comprising a cable having a cable proximal end and a cable distal end, a winding defining a bore, and a plunger comprising an elongated rod having a plunger first end and an opposite plunger second end, the plunger first end adapted to be slidingly received within the bore, the plunger second end extending from the bore, the plunger second end including a plurality of through holes, each through hole defining an eyelet adapted to accept the cable proximal end therethrough. The cable proximal end is threaded through at least one through hole and coupled to the plunger. The cable distal end is coupled to the lever. The winding is adapted to, when energized, position the plunger in a first position to cause cable tension to pull on the lever to disengage the lever head from the latching mechanism, and when not energized, position the plunger in a second position to release cable tension and enable a restoring spring to engage the lever head with the latching mechanism.
The foregoing is not intended to be a limiting description of the invention as persons skilled in the art are capable of appreciating other embodiments and features for the following detailed description in conjunction with the drawings.
In the following detailed description, reference is made to the accompanying drawings which form a part hereof wherein like numerals designate like parts throughout, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
Embodiments of the present invention provide a solenoid plunger for a solenoid actuator having a plurality of eyelets that overcome the problems and issues associated with plungers having a single eyelet. The following detailed description describes a particular type of solenoid actuator. It is understood that other types of solenoid actuators, having other specific means for moving a plunger, and other modes of operation, such as, but not limited to pull-type, push-type and hold-type, are particularly suitable for embodiments of the plunger of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
Embodiments of the present invention further discussed below provide the use of a crimping tab to secure a cable distal end of a cable to the plunger. It is understood that those in the art will recognize that there are many types of methods and fasteners that can be used to secure the cable distal end to the plunger as well as to form and secure a loop in the cable distal end. Examples of suitable methods include, but are not limited to, tying one or more knots in the cable distal end. Examples of suitable fasteners include, but are not limited to, the mentioned crimping tab, a screw clamp, a spring clip, and a nut and bolt assembly. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
The ability of looping the cable 30 through a plurality of eyelets 24 provides a significant unrealized benefit of substantially eliminating retrograde positioning of the loop 35, as compared to looping the cable 30 through a single eyelet 14 as shown in
Where the loop 35 can move within the eyelet 14, such as in the case where the cable 30 and the eyelet 14 is not substantially the same diameter or closely fitted, among others, there is the possibility that the loop 35 can move from the plunger first side 18a of the plunger second end 18 to the plunger second side 18b causing retrograde positioning of the loop 35 with substantially the same consequences as discussed above, as shown in
Embodiments of the present invention substantially eliminate retrograde positioning of the loop 35. Referring again to
Looping the cable 30 through a plurality of eyelets 24 provides significant operational effectiveness, for being much more forgiving in circumstances wherein the loop 35 is caused to enlarge due to stretching over time or improper tensioning when installed, as compared to looping the cable 30 through a single eyelet 14 as shown in
Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve the same purposes may be substituted for the specific embodiment shown and described without departing from the scope of the present invention. Those with skill in the art will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of this invention and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein.
This invention claims the benefit of co-pending U.S. Provisional Application No. 60/518,478, entitled “SOLENOID ACTUATOR”, filed Nov. 4, 2003, the entire disclosure of which is hereby incorporated by reference as if set forth in its entirety for all purposes.
Number | Name | Date | Kind |
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795340 | Carichoff | Jul 1905 | A |
3119954 | Bachi | Jan 1964 | A |
3152289 | Panfilo | Oct 1964 | A |
20020053803 | Kuntz et al. | May 2002 | A1 |
Number | Date | Country | |
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20050093662 A1 | May 2005 | US |
Number | Date | Country | |
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60518478 | Nov 2003 | US |