CABLE GUIDE TENSIONER FOR REGULATOR SYSTEM
Methods and apparatus for applying tension to a cable in a regulator system, include: permitting the cable to slide over a length of the peripheral surface extending between an entry point and exit point on a cable guide tensioner; and urging the cable guide tensioner to rotate where the rotation results in varying at least one of the length and a distance between the entry point and exit point, and induce tension in the cable.
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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 INVENTIONOne 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.
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.
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.
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
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.
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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
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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.
Claims
1. A regulator system, comprising:
- an object;
- a cable coupled to, and operating to move, the object in response to a driving source; and
- at least one cable guide tensioner including first and second spaced apart opposing surfaces, and a peripheral surface extending between the first and second surfaces, the at least one cable guide tensioner operating to:
- (i) slidingly engage the cable over a length of the peripheral surface, the length extending between an entry point and exit point; and
- (ii) vary at least one of the length and a straight-line distance between the entry point and the exit point as a function of rotation about a pivotal axis, the pivotal axis extending transversely through the first and second opposing surfaces.
2. The regulator system according to claim 1, wherein peripheral edges of the first and second opposing surfaces circumscribe shapes selected from the group consisting of: a circle, an oblong shape, a curvilinear shape, an ellipse and an oval.
3. The regulator system according to claim 1, wherein the pivotal axis is located at a position such that at least one of the length and the straight-line distance increases as the cable guide tensioner rotates about the pivotal axis.
4. The regulator system according to claim 3, further comprising:
- a biasing mechanism that urges the cable guide tensioner to rotate about the pivotal axis;
- a stationary surface that operates to provide a base about which the cable guide tensioner can rotate; and
- a connecting mechanism that operates to connect the cable guide tensioner to the stationary surface.
5. The regulator system according to claim 4, wherein the biasing mechanism comprises at least one spring having first and second ends, the first end of the spring coupled to the first opposing surface of the cable guide tensioner and the second end coupled to the stationary surface.
6. The regulator system according to claim 4, wherein the cable guide tensioner further comprises a rod disposed transversely on the first opposing surface and engages a channel located in the stationary surface and functions to guide the cable guide tensioner along the channel.
7. The regulator system according to claim 6, wherein the biasing mechanism comprises at least one spring having first and second ends, the first end of the spring adjacent being coupled to the channel located in the stationary surface and the second end of the spring being coupled to the rod of the cable guide tensioner, and the at least one spring operating to urge the cable guide tensioner to rotate about the pivotal axis.
8. The regulator system according to claim 4, wherein the stationary surface is integrated with a carrier module of a vehicle door panel.
9. The regulator system according to claim 4, wherein:
- the connecting mechanism further comprises a ratchet apparatus having a first set of teeth disposed on the first opposing surface of the cable guide tensioner, and a second set of teeth disposed on the stationary surface; and
- the first and second sets of teeth are situated and shaped such that engagement thereof permits the cable guide tensioner to rotate about the pivotal axis only in one direction.
10. The regulator system according to claim 4, wherein:
- the cable guide tensioner further comprises an aperture extending through at least one of the first and second opposing surfaces at the pivotal axis; and
- the connecting mechanism further comprises a shaft having first and second ends, the shaft extending through the aperture of the cable guide tensioner and coupling to the stationary surface such that the cable guide tensioner is rotatable about the shaft.
11. The regulator system according to claim 10, wherein:
- the connecting mechanism further comprises a ratchet apparatus having a first set of teeth disposed on the first opposing surface of the cable guide tensioner, and a second set of teeth disposed on the stationary surface; and
- the first and second sets of teeth are situated and shaped such that engagement thereof permits the cable guide tensioner to rotate about the pivotal axis only in one direction.
12. The regulator system according to claim 11, wherein the connecting mechanism further includes at least one compliance spring coaxial with the shaft, and operating to provide a spring force to expand a distance between the cable guide tensioner and the stationary surface and to urge the first and second plurality of teeth to snugly engage one another while also providing a sufficient amount of give to allow the first and second sets of teeth to slide over one another.
13. The regulator system according to claim 12, wherein at least one compliance spring is situated between the cable guide tensioner and the stationary surface.
14. The regulator system according to claim 12, wherein at least one compliance spring is situated between the cable guide tensioner and the stationary surface and a second compliance spring is situated between a widened end cap and the opposing surface of the cable guide tensioner.
15. The regulator system according to claim 11, wherein the cable guide tensioner further comprises at least one integrated spring finger disposed on the first opposing surface and operates to provide a spring force to expand a distance between the cable guide tensioner and the stationary surface and to urge the first and second plurality of teeth to snugly engage one another yet provide a sufficient amount of give to allow the first and second sets of teeth to slide over one another.
16. The regulator system according to claim 11, wherein the stationary surface further comprises at least one integrated spring finger thereon and operates to provide a spring force to expand the distance between the cable guide tensioner and the stationary surface and urge the first and second plurality of teeth to snugly engage one another yet provide a sufficient amount of give to allow the first and second sets of teeth to slide over one another.
17. The regulator system of claim 1, further comprising at least one pulley that is connected to a motor and functions to drive the cable.
18. The regulator system of claim 1, wherein one of:
- the object is a window and the base structure is a carrier module of a vehicle door;
- the object is a sunroof of a vehicle;
- the object is a sliding door of a vehicle;
- the object is a lift gate of a vehicle;
- the object is a lift platform of a handicap ramp for a vehicle; and
- the object is a movable portion of a vehicle seat.
19. A method of applying tension to a cable in a regulator system, comprising:
- permitting the cable to slide over a length of a peripheral surface of a cable guide tensioner having an entry point and an exit point; and
- rotating the cable guide tensioner such that at least one of the length and a straight-line distance between the entry point and exit point are increased and induce tension in the cable.
20. The method of claim 19, further comprising:
- permitting the cable guide tensioner to rotate in one direction that results in increasing at least one of the length and the straight-line distance between the entry point and exit point, and prohibiting the cable guide tensioner from rotating in an opposite direction.
Type: Application
Filed: Apr 10, 2009
Publication Date: Oct 14, 2010
Applicant: FAURECIA INTERIOR SYSTEMS U.S.A., INC. (Auburn Hills, MI)
Inventor: Michael J. Twork (White Lake, MI)
Application Number: 12/421,944
International Classification: B65H 77/00 (20060101); B65H 59/20 (20060101);