Method for mounting non-acceleration based sensor

Abstract

A mounting assembly includes a pair of fingers upturned from a surface on which the sensor is mounted. The fingers are spaced a distance apart and the sensor is mounted between the fingers. Extending between the fingers is an elastic member. This elastic member extends over the sensor and secures the sensor onto the mounting surface. Another mounting assembly according to this invention includes a catch that extends upward from the mounting surface and a corresponding key portion disposed on the sensor. A fastening member corresponding with the sensor maintains the sensor in the received position within the catch member.

Description

[0001] This application claims priority to U.S. Provisional Application No. 60/466,516 filed on Apr. 28, 2003 and U.S. Provisional application No. 60/497,572 filed on Aug. 25, 2003.

BACKGROUND OF THE INVENTION

[0002] This application relates to a mounting assembly for securing a sensor to a vehicle, and specifically to a mounting assembly for securing a sensor to a motor vehicle component without the use of threaded fasteners.

[0003] Typically, sensors are mounted throughout a motor vehicle to monitor a desired condition. Each of these sensors requires a mounting assembly to secure the sensor to the desired location. In most sensor mounting applications it is common to use a conventional threaded fastener. Typically, a screw or bolt is threaded through an opening within the sensor and into a threaded opening within the vehicle component. Conventional threaded fasteners can be expensive, and time consuming to install.

[0004] As appreciated, in many instances sensors are mounted within harsh and hostile environments such as within a wheel well or in close proximity to heat producing elements. Disadvantageously, in these hostile environments conventional threaded fasteners can become corroded and damaged, preventing disassembly of the sensor from the motor vehicle. In such cases the threaded fasteners must be cut and new fasteners must be obtained and used for remounting of the existing sensor or a new sensor.

[0005] In many applications, a sensor must be mounted securely to accurately sense movement of a vehicle component. This is especially true with the use of acceleration-based sensors. Such sensors measure movement of the vehicle component for use by other systems. However, for non-acceleration based sensors such rigid mounting is not necessary.

[0006] Accordingly, it is desirable to develop and design a mounting assembly for non-acceleration based sensors that is easily incorporated into existing design and does not require the use of threaded fasteners.

SUMMARY OF THE INVENTION

[0007] This invention is a mounting assembly for a sensor that provides for mounting to a vehicle component without the use of threaded fasteners.

[0008] A mounting assembly of this invention includes a base having a pair of fingers upturned from a surface on which the sensor is mounted. The fingers are spaced a distance apart and the sensors mounted between the fingers. Extending between the fingers is an elastic member. This elastic member extends over the sensor and secures the sensor onto the mounting surface. The sensor assembly includes corresponding parts that engage alignment features that extend upward from the mounting surface. These alignment features prevent movement of the sensor relative to the mounting surface. The elastic member prevents movement of the sensor away from the mounting surface to prevent the sensor from sliding along the mounting surface.

[0009] Another mounting assembly according to this invention includes a catch that extends upward from the mounting surface and a corresponding key disposed on the sensor. The key of the sensor is received within the catch. A non-threaded fastening member secures the sensor on a side opposite the key. The sensor is thereby secured to the mounting surface without the use of a threaded fastener.

[0010] Another mounting assembly according to this invention includes a channeled slot that the sensor slides into. The sensor slides into the channeled slot and is secured by at least one interference feature disposed on the mounting surface. The interference feature engages the upper portion of the sensor to prevent the sensor from sliding out of the channeled slot. The sensor and channeled slot include interference features that secure and maintain the sensor in a desired location. The interference features provide for mounting of the sensor without the use of additional fasteners.

[0011] Another mounting assembly according to this invention includes fingers that extend upward from the mounting surface and through openings within the sensor. An interference fastener is attached to the finger to hold the sensor against the mounting surface. The finger can also be deformed to prevent removal of the sensor instead of using the interference fasteners. Further, the fingers can be in integral part of the mounting surface or can be inserted from an opposite side of the mounting surface into openings within the sensor. The resulting fit secures the sensor to the mounting surface.

[0012] Accordingly, the mounting assembly of the invention provides a cost effective alternative to threaded fasteners that is easily adaptable to existing sensors and mounting surfaces.

[0013] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a prospective view of a mounting assembly for sensor according to this invention.

[0015] FIG. 2 is a side view of a sensor mounted according to this invention.

[0016] FIG. 3 is a plan view of a sensor secured to a base according to the mounting assembly of this invention.

[0017] FIG. 4A is a side view of a sensor prior to mounting with the mounting assembly of this invention.

[0018] FIG. 4B is a side view of the sensor mounted to the mounting surface according to this invention.

[0019] FIG. 5 is a cross-sectional view of a sensor assembly mounted with a mounting assembly according to this invention.

[0020] FIG. 6 is a cross-sectional view of a sensor mounted to a vehicle component according to another mounting assembly of this invention.

[0021] FIG. 7 is a side view illustrating the method of inserting the sensor into the mounting assembly according to this invention.

[0022] FIG. 8 is a cross-sectional view of another mounting assembly according to this invention.

[0023] FIG. 9 is a front view of a sensor mounted with another mounting assembly according to this invention.

[0024] FIG. 10 is a side view illustrating how the sensor is received within a mounting assembly according to this invention.

[0025] FIG. 11 is a side view of a sensor secured within a mounting assembly of this invention.

[0026] FIG. 12 is a side view of a sensor secured by another mounting assembly according to this invention.

[0027] FIG. 13 is a cross-sectional view of another mounting assembly according to this invention.

[0028] FIG. 14 is a side view of another mounting assembly according to this invention including bendable arms for receiving a sensor assembly.

[0029] FIG. 15 is a side view of another mounting assembly according to this invention.

[0030] FIG. 16 is side view of another mounting assembly according to this invention.

[0031] FIG. 17 is a prospective view of non-threaded fastener utilized to secure the sensor to the mounting surface.

[0032] FIG. 18 is a side view of another mounting assembly according to this invention including attachment members extending from a mounting surface.

[0033] FIG. 19 is side view of another mounting assembly according to this invention.

[0034] FIG. 20 is an enlarged view of a tab and slot for the mounting assembly of FIG. 19.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0035] Referring to FIG. 1, a mounting assembly 10 is shown that secures a sensor 12 to a base 14. The mounting assembly 10 includes an elastic member 20. The elastic member 20 is stretched between fingers 16. The fingers 16 extend upward from the base 14 and are spaced a distance apart. The sensor 12 is secured between the upwardly extended fingers 16 by the downward biasing force exerted by the elastic member 20 on the sensor 12.

[0036] Referring to FIG. 2, preferably, the fingers 16 are stamped out features formed within the base 14. However, it is within the contemplation of this invention that the fingers 16 may be of any configuration capable of holding the elastic member 20. The elastic member 20 is preferably comprised of a material compatible with the conditions in which the sensor 12 is mounted. As appreciated, many materials are known and understood by workers skilled in the art that are capable of enduring the specific conditions in which the sensor 12 may be mounted.

[0037] The base 14 includes alignment features for securing the sensor 12 in place between the fingers 16. Preferably, the alignment features are tabs 18 that extend upward from the surface 22. The tabs 18 engage corresponding openings 19 formed within the sensor 12. The tabs 18 prevent the sensor 12 from sliding across a surface 22 of the base 14. The elastic member 20 prevents the sensor 12 from moving away from the surface 22 of the base 14. This provides a secure mounting of the sensor 12 without the use of threaded fasteners.

[0038] Referring to FIG. 3, the mounting assembly 10 can include two pairs of fingers 16 disposed along the sensor 12. Each set of fingers 16 also includes an elastic member 20. As appreciated, the use of more than one elastic member 20 disposed across the sensor 12 provides additional biasing force for securing the sensor 12. Further, additional fingers 16 and elastic member 20 also provide for the securing of sensors 12 of differing configurations. As appreciated, a larger sensor 12 may require additional elastic members 20 for securing against the surface 22 of the base 14. A worker skilled in the art with the benefit of this disclosure will understand that multiple pairs of fingers 16 and elastic members 20 can be used dependent on application specific requirements and are within the contemplation of this invention. Further, the elastic members 20 stretched between fingers 16 are shown disposed laterally across the fingers 16. The elastic members 20 may also by crossed between fingers 16 to provide a desired fastening arrangement.

[0039] Referring to FIGS. 4A and 4B, the elastic member 20 is secured to the sensor 12 at a fastening point 24. Pre-fastening the elastic member 20 to the sensor 12 eliminates loose parts during assembly operations where the sensor 12 is mounted to the base 14. During this assembly process the sensor 12 is placed on the base 14. The tabs 18 fit into the openings 19 within the sensor 12. The elastic member 20 is then stretched over the projecting fingers 16 to secure the sensor 12 to the base 14. As appreciated, the fastening point 24 can be of any type known to a worker skilled in the art. In one such configuration the fastening point 24 may be a clip or tab onto which the elastic member 20 is assembled. As appreciated, it is within the contemplation of this invention to utilize other configurations for holding the elastic member 20 in place on the sensor 12.

[0040] Referring to FIG. 5, another alignment feature is shown that includes holes 26 within the base 14. The sensor 12 includes tabs 28 that project downward into the holes 26 to prevent lateral and longitudinal movement of the sensor 12 relative to the base 14. As appreciated, the specific configuration of the alignment features can vary according to the specific sensor configuration.

[0041] Referring to FIG. 6, another mounting assembly 40 according to this invention includes a catch 42 extending upward from the surface 22 of the base 14. The catch 42 defines a pocket 54. The pocket 54 receives a tab 46 disposed on the sensor 44. A flange 50 is disposed on the sensor 44 adjacent an end distal from the tab 46. The flange 50 includes an opening 51 through which a fastening member 48 extends to an opening 52 in the base 14. The fastening member 48 provides an interference fit within the opening 51 within the flange 50 and the opening 52 within the base 14.

[0042] Referring to FIG. 7, the sensor 44 is shown during insertion into the pocket 54. The tab 46 is received into the pocket 54 and the flange 50 is secured against the surface 22 by the fastening member 48. The fastening member 48 is then extended through the opening 51 within the flange 50 of the sensor 44 and into the opening 52 in the base 14. This method of securing the sensor 44 provides positive mounting and alignment of the sensor 44 without the use of threaded fasteners. Further, the use of the pocket 54 and tab 46 eases assembly and reduces mounting assembly complexity.

[0043] The fastening member 48 preferably includes a plurality of deformable extensions extending from a longitudinal member. The fastening member 48 is pressed into openings 51 and 52 such that the deformable extensions compress inwardly toward the longitudinal member, and re-extend once free from the confines of the openings 51 and 52.

[0044] Referring to FIG. 8, another mounting assembly 60 according to this invention includes a catch 42 extending from the base 14 and including a slot 62. The slot 62 receives a lip 64 disposed on the sensor 44. Sensor 44 also includes the flange 50 with opening 51 for the fastening member 48 on the side opposite the lip 64. In this embodiment the catch 42 includes the slot 62 instead of forming the pocket 54. This configuration provides an alignment function as well as receiving and securing the sensor 44 to the base 14.

[0045] Referring to FIG. 9, another mounting assembly 70 according to this invention includes a first channel 74 and a second channel 76. The first and second channels 74, 76 define a pocket 78 therebetween for a sensor 72. The first and second channels 74, 76 are preferably disposed in a manner such that the sensor 72 is biased toward remaining within the pocket 78 by the weight of the sensor 72. The weight of the sensor 72 holds the sensor 72 within the pocket 78 formed by the first and second channels 74, 76. Preferably the sensor 72 fits into the pocket 78 in an interference manner such that the sensor 72 will not bounce or vibrate relative to the channels 74, 76. Interference bumps 80 are disposed proud of the surface 22 to prevent the sensor 72 from sliding from the pocket 78.

[0046] Referring to FIG. 10, the sensor 72 may be removed by pulling up and outward. The interference bumps 80 are positioned adjacent an upper end of the sensor 72 when in the assembled position. Installation is facilitated by inserting the sensor 72 into the pocket 78 such that an upper portion of the sensor 72 is disposed adjacent the interference bump 80.

[0047] Referring to FIG. 11, the mounting assembly 70 is shown in a side view with the sensor 72 mounted within the pocket 78 formed by the channels 74, 76. Interference bump 80 has a rounded surface providing for insertion of this sensor 72 into the pocket 78 but interferes with removal of sensor 72. The interference bump 80 prevents movement of the sensor 72 out of the pocket 78. The mounting assembly 70 provides a simple and effective means of securing the sensor 72 to a vehicle component without the use of threaded fasteners.

[0048] Referring to FIG. 12, another mounting assembly 90 according to this invention is shown in cross-section. The sensor 92 includes a t-shaped channel 96 that fits within a c-shaped channel 94 that is disposed on the base 14. The t-shaped channel 96 slides over the c-shaped channel 94 disposed on the base 14. The base 14 includes a locking feature that includes a ramp 98 adjoining a flat 97. The t-shaped channel 96 includes a shoulder 99 that rides over the ramp 98 to lock against the flat 97 adjoining the ramp 98. The shoulder 99 abuts the flat 97 to prevent movement of the sensor 92 off the c-shaped channel 94 of the base 14. The ramp 98 prevents the sensor 92 from being removed from the c-shaped channel 94 once received therein and the shoulder 99 is seated against the flat 97 of the locking feature.

[0049] During assembly, the sensor 92 slides over the ramp 98 and into the c-shaped channel 94. The shoulder 99 engages the flat 97 of the ramp 98 to hold the sensor 92 within the c-shaped channel 94. The c-shaped channel 94 further includes an interference point 102. This interference point 102 corresponds with the t-shaped channel 96 of the sensor 92 to provide an interference fit there between. The interference fit substantially prevents movement of the sensor 92 within the mounting assembly 90.

[0050] Referring to FIG. 13, a mounting assembly 90′ includes a t-shaped tab 106 extending upward from the base 14. The t-shaped tab 106 is disposed on the base 14 and corresponds with a c-shaped channel 108 disposed on the sensor 92′. The c-shaped channel 108 is received by the t-shaped tab 106 to secure the sensor onto the base 14. The t-shaped tab 106 received within the c-shaped channel 108 provides positive placement and attachment of the sensor 92′ to the base 14.

[0051] Referring to FIG. 14, another mounting assembly 120 according to this invention includes a plurality of bendable arms 122. Each of the bendable arms 122 is disposed to define a pocket 118 into which a sensor 121 is secured. The bendable arms 122 are bendable outwards to receive the sensor 121. Each bendable arm 122 includes a lock 124. The lock 124 includes a lead-in surface 126 and a flat 128. The bendable arms 122 bend outwardly away from each other responsive to the sensor 121 being pressed downwardly against the lead-in surface 126 of each of the bendable arms 122. The bendable arms 122 then move outwardly to receive the sensor 121. Once the sensor 121 has cleared the lead-in surface 126 the bendable arms 122 snap back into their original position. The flat 128 of each of the bendable arms 122 overlaps a portion of the sensor 121. The flat 128 overlaps the sensor 121 and secures the sensor 121 against the surface 22. Preferably, there is a slight interference fit between the flat 128 and the sensor 121 to maintain a desired position without jostling or vibration.

[0052] Referring to FIG. 15, another mounting assembly 130 according to this invention includes the base 14 that has openings 136. The openings 136 correspond with openings 138 within a sensor 132. Interference members 134 extend through openings 136 and into the openings 138.

[0053] Referring to FIG. 16, another mounting assembly 130′ includes a pair of attachment members 140 that are integral parts of the base 14. Each of the attachment members 140 extends transversely from the surface 22 of the base 14. The sensor 132 includes the corresponding opening 138 that receive the attachment members 140. The sensor 132 is assembled onto the attachment members 140 and slide down adjacent the surface 22. The sensor 132 is held adjacent to surface 22 by clips 142 that are assembled onto the attachment members 140 to hold the sensor 132 against the surface 22. Preferably, the clips 142 include an opening that provides an interference with the attached members 140.

[0054] Referring to FIG. 17, the clip 142 includes an opening 143 and plurality of tabs 145 that are disposed about the opening 143. Insertion of the clip 142 to the attachment members 140 provides an interference fit that prevents removal of the sensor 132 without a considerable and potentially destructive force.

[0055] Referring to FIG. 18, another embodiment of the mounting assembly 130″ includes the attachment members 140 that are deformed over the openings 138 of the sensor 132 to hold the sensor 132 in place. Preferably, the attachment members 140 are heat stacked as indicated at 144 to deform the material comprising the attachment member 140 to secure the sensor 132 to the base 14.

[0056] Heat staking of the attachment members 140 deforms ends of the attachment members 140 to hold the sensor 132 adjacent the surface 22. Heat staking of the attachment members 140 provides the advantage of reducing the number of parts that are required for mounting of the sensor 132. The heat stake of the attachment member 140 does not require additional attachment devices or clips.

[0057] Referring to FIGS. 19 and 20, another mounting assembly 150 includes a bracket 154 attached to a frame 164. The sensor 152 is attached to the bracket 154. The bracket 154 extends about a side and bottom of the frame 164. The bracket 154 includes a tab 156 received within a slot 158 of the frame 164 and a flange 166 for a fastener 160. The bracket 154 provides for the installation of the sensor 152 in locations where it is difficult to obtain access to each side of the frame member 164. The tab 156 fits into a slot 158 on the frame 164 and the flange 166 swings around to the bottom of the frame 164 for securing by the fastener 160. The tab 156 on the bracket 154 engages the slot 158 in the frame 164 such that the sensor 152 can only be removed by being rotated such that the tab 156 is free of the slot 158.

[0058] The mounting assemblies of this invention provide for mounting of a non-acceleration based sensors without the use of threaded fasteners. Further, the mounting assemblies of this invention reduce assembly time and complexity.

[0059] Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.

Claims

1. A mounting assembly for a sensor comprising:

a base comprising a pair of fingers spaced a distance apart for receiving the sensor there between; and

an elastic member stretched between said fingers and extending across said distance between said fingers, wherein the sensor is securable between said base and said elastic member.

2. The assembly as recited in claim 1, wherein said base comprises a locating member for aligning the sensor between said fingers.

3. The assembly as recited in claim 2, wherein said locating member extends above a surface of said base member.

4. The assembly as recited in claim 2, wherein said locating member comprises openings within said base.

5. The assembly as recited in claim 1, comprising two pair of fingers and two elastic members stretched between said fingers.

6. A mounting assembly for a sensor comprising:

a catch member extending upward from a base;

a key disposed on the sensor corresponding with said catch member; and

a securing member corresponding with the sensor for maintaining the sensor in said received position within said catch member.

7. The assembly as recited in claim 6 wherein said catch member comprises a slot and said key comprises a tab received within said slot.

8. The assembly as recited in claim 7, wherein said catch member extends transversely from said base, and said slot is spaced apart from said base.

9. The assembly as recited in claim 7, wherein said catch member comprises a pocket and said key comprises a lip received within said pocket.

10. The assembly as recited in claim 9, wherein said pocket is disposed adjacent a surface of said base, and said lip rests on said surface of said base portion when received within said pocket.

11. The assembly as recited in claim 7, wherein said catch member comprises a first and second channels spaced a distance apart for receiving the sensor therebetween.

12. The assembly as recited in claim 11, wherein said sensor includes a body, said body comprising the key received within said first and second channels.

13. The assembly as recited in claim 11, wherein said first and second channels sections form a C-shaped channel adjacent a surface of said base.

14. The assembly as recited in claim 11, wherein said securing member comprises at least one interference bump extending above a surface of said base and contacting some portion of the sensor for inhibiting movement of the sensor from said first and second channels.

15. The assembly as recited in claim 11, wherein said securing member comprises a ramp corresponding with a tab disposed on the sensor.

16. The assembly as recited in claim 15, wherein said first and second channels comprise an interference fit with the sensor.

17. The assembly as recited in claim 16, wherein said first and second channels include a ramped lead in surface for the sensor.

18. The assembly as recited in claim 6, wherein said catch member comprises a T-shaped tab, and said key comprises a C-shaped channel corresponding with said T-shaped tab.

19. The assembly as recited in claim 6, wherein said catch member comprise a C-shaped channel and said key comprises a T-shaped tab received within said C-shaped channel.

20. The assembly as recited in claim 6, wherein said catch member comprises a plurality of bendable arms extending transversely from a surface of said base and said securing member is disposed on an end of said bendable arm.

21. The assembly as recited in claim 20, wherein said key disposed on the sensor comprises a body of the sensor.

22. The assembly as recited in claim 21, wherein said body is received within a space defined between said plurality of bendable arms and held adjacent a surface of said base by said securing member.

23. A mounting assembly for a sensor comprising:

a base comprising an attachment member extending transversely to a surface of said base; and

an opening defined by the sensor for receiving said attachment member.

24. The assembly as recited in claim 23, wherein said attachment member is an integral portion of said base portion.

25. The assembly as recited in claim 24, wherein said attachment member is deformable to hold the sensor between a deformed portion of said attachment member and said base.

26. The assembly as recited in claim 24, comprising a securing member attachable to said attachment member for holding the sensor adjacent said base.

27. The assembly as recited in claim 23, wherein said attachment member extends through openings in said base and into the sensor.

28. The assembly as recited in claim 23, wherein said attachment member comprises an interference member received within the sensor.