Abstract:
A switch mounted on the push rod of a master cylinder assembly and controlling in sequence several switches such, for example, as a cruise control switch, an electronic fuel injection switch, and a start interlock switch. The switch includes a hollow housing defining a central chamber through which the push rod passes and a plunger assembly carried by the push rod and mounted for axial movement within the chamber. The plunger assembly includes a primary plunger and a secondary plunger carried by and movable axially relative to the primary plunger. The initial portion of the forward movement of the push rod allows incremental forward movement of the secondary plunger to actuate a first series of switches whereafter the push rod moves further forwardly without either plunger whereafter the push rod engages the primary plunger to move the plunger assembly forwardly to actuate a further switch. The lost or relative movement between the push rod and the plunger assembly allows the switch housing to be significantly shortened and thereby allows the switch to be utilized on relatively short push rods.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to an electrical switch operated by the input member of a hydraulic master cylinder assembly, such as the master cylinder of a motor vehicle clutch hydraulic control system or the master cylinder of a motor vehicle hydraulic brake system. 
     It has become general practice in the automobile industry to interlock the operation of the engine starter motor with other controls of the motor vehicle such that the starter member is rendered inoperative unless the transmission is in neutral or park in motor vehicles provided with an automatic transmission or, in motor vehicles provided with a foot operated clutch and a manually operated gear shift transmission, unless the transmission is in neutral and/or the clutch pedal is fully depressed, to fully release the clutch. In addition, it is convenient in a motor vehicle provided with a cruise control and a mechanical clutch to shut off the operation of the cruise control upon, for example, downshifting which in turn requires release of the clutch. However, it is necessary that the cruise control be disconnected even before the clutch is fully released to enable the driver to cut ore the cruise control by a slight foot tap on the clutch pedal. It is also desirable to actuate the electronic fuel control (EFI) of the motor vehicle in response to the initial depressing movement of the clutch. 
     Many switch arrangements have been provided for use in association with the master cylinder assembly to accomplish the various desired switching operations as the clutch pedal is depressed. Examples of such switches are shown, for example, in U.S. Pat. Nos. 4,878,041, 4,719,444, 474219 and 4,649,238. The switch devices shown in these prior art patents are all of the type in which the switch mounts on the push rod of the master cylinder assembly and in which the switch includes a plurality of axially spaced switches which can be sequentially actuated in response to depression of the clutch to generate a sequential series of control signals with respect to cruise control, EFI interlock, etc. Whereas these prior art switches have proven to be generally satisfactory, generating the required control signals in response to depression of the clutch, the sequential arrangement of the various switches along the length of the switch results in a relatively long switch assembly which is incompatible with the relatively short push rods that are found in many present day motor vehicles. 
     SUMMARY OF THE INVENTION 
     This invention is directed to the provision of an improved master cylinder switch. 
     More specifically, this invention is directed to the provision of a master cylinder switch that fits over the push rod of the master cylinder and that is compact enough to use even with very short push rods. 
     The invention relates to a hydraulic master cylinder assembly of the type including a master cylinder, a piston mounted in the master cylinder, a push rod projecting at its forward end into the rear end of the master cylinder for connection to the piston, and a switch assembly positioned on the push rod and including a hollow switch housing defining axially spaced first and second switch means and a plunger assembly mounted for sliding movement in the housing in response to forward movement of the push rod to Sequentially coact with the housing switch means to actuate the switch means to generate sequential first and second control signals. 
     According to the invention, in the initial increment of forward movement of the push rod, the plunger assembly acts to actuate the first switch means, in the second increment of forward movement of the push rod the push rod moves forwardly relative to the plunger assembly, and in the third increment of forward movement of the push rod the plunger assembly moves forwardly with the push rod to actuate the second switch means. This arrangement allows the push rod to move relative to the plunger assembly between the actuation of the first and second switch means so as to reduce the overall length of the switch housing and allow the switch to be used on even very short push rods. 
     According to a further feature of the invention, the plunger assembly includes a first plunger member and a second plunger member mounted on the first plunger member and axially movable relative to the first plunger member and the actuation of the first switch means upon the initial increment of forward movement of the push rod comprises movement of the second plunger member with the push rod and relative to the first plunger member. The provision of a two-part plunger assembly allows the switch actuating functions of the plunger assembly to be separated to further facilitate the provision of an extremely short switch assembly. 
     According to a further feature of the invention, the first switch means is spring biased to a first position and movable against the resistance of the spring to a second position; with the push rod in the fully rearwardly extending position the second plunger member maintains the first switch means in its second position; and as the push rod undergoes its initial increment of forward movement it releases the second plunger member and allows it to move forwardly with the push rod to allow the first switch means to move to its first position under the bias of the switch means. This arrangement allows the built-in bias of the switch means to perform the initial switching function. 
     According to a further feature of the invention, the push rod defines first and second axially spaced radially extending actuating surfaces; with the push rod in its fully rearwardly extending position, the first actuating surface precludes forward movement of the second plunger member so as to maintain the first switch means in its second position; and the second actuating surface engages the plunger assembly as the push rod begins its third increment of forward movement. This specific arrangement facilitates the provision of lost motion as between the push rod and the plunger assembly. 
     According to a further feature of the invention, the first actuating surface coacts with a forwardly facing surface on the second plunger member; the second actuating surface coacts with a rearwardly facing surface on the first plunger member; and the actuating surfaces are spaced axially by a distance greater than the distance between the forwardly and rearwardly facing surfaces on the plunger assembly so that the push rod undergoes forward movement relative to the plunger assembly following the movement of the first switch means to its first position and prior to engagement of the plunger assembly by the second actuating surface. 
     According to a further feature of the invention, the first and second actuating surfaces comprise first and second annular shoulder surfaces on the push rod. In the disclosed embodiment of the invention, one of the annular shoulders comprises a shoulder formed at the juncture of a large diameter portion of the push rod with a reduced diameter portion of the push rod portion and the other annular shoulder is defined by a ring fixedly secured to the reduced diameter portion of the push rod. 
     In the disclosed embodiment of the invention, the hollow switch housing includes a rear end wall and an annular interior surface extending forwardly from the rear end wall and in surrounding relation to the central axis of the push rod; the first switch means is provided on the housing rear end wall; the second switch means is provided on the housing interior annular surface; and the plunger assembly includes a first plunger member mounted for sliding movement on the housing annular surface for coaction with the second switch means on the annular surface and a second plunger member carried by, and movable axially relative to, the first plunger member for coaction with the first switch means on the rear end wall of the housing. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a fragmentary somewhat schematic view of a master cylinder assembly including a master cylinder switch according to the invention; 
     FIG. 2 is a perspective view of the master cylinder switch; 
     FIG. 3 is a cross-sectional view of the master cylinder switch; 
     FIGS. 4-15 are cross-sectional views taken where indicated on FIG. 3; 
     FIGS. 16 and 17 are detailed views of a plunger assembly utilized in the invention switch; 
     FIG. 18 is an exploded perspective view of a modified form of master cylinder switch according to the invention; and 
     FIG. 19 is a cross-sectional view taken on line 19--19 of FIG. 18. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The invention master cylinder switch assembly is seen in FIG. 1 in association with a motor vehicle of the type including a fire wall 10, a control pedal 12 (such as a clutch pedal or a brake pedal) positioned on the lower end of a pivotally mounted pedal arm 14; a master cylinder 16 secured in known manner to the front face of the fire wall 10 and projecting at its forward portion 16a through and forwardly of the fire wall; a piston 18 mounted for reciprocal movement in the cylinder 16; and a push rod 20 pivotally secured at its rear end to control arm 14 and pivotally associated at its forward end with piston 18 so that, in known manner, as pedal 12 is depressed, push rod 20 moves forwardly into the rear end of the master cylinder to move the piston 18 forwardly within the cylinder and transmit pressurized hydraulic fluid through conduit 21 for use by a suitable slave cylinder to actuate, for example, a clutch or brake of the motor vehicle). The invention switch assembly 22 is mounted on the push rod 20 rearwardly of the master cylinder and within the passenger compartment. 
     Switch assembly 22 includes a housing 24, a plunger assembly 25, springs 26, a cruise control switch 27, an EFI switch 28, and interlock switch contact strips 29. 
     Housing 24 is formed of a suitable plastics material and includes an annular central main body member 24a including an upstanding contact housing portion 24b; a rear end wall member 24c fixedly secured to the rear end of annular main body member 24a, defining a central aperture 24d for passage of the push rod 20j, and further defining a pair of parallel forwardly extending guide rod portions 24e disposed on opposite sides of the central axis 30 of the push rod; and a front end wall member 24f fixedly secured to the front annular edge of the annular central main body member 24a and including a hub portion 24g and apertures 24h sized to receive the forward ends 24i of the guide rod portions 24e of rear end wall member 24c. Annular main body portion 24a defines a cylindrical interior axially extending surface 24j, a pair of parallel upper axially extending ridge portions 24k, and a pair of parallel lower axially extending ridge portions 24m. 
     Plunger assembly 25 includes a primary plunger member 32 and a secondary plunger member 34 both formed of a suitable plastics material. 
     Primary plunger member 32 has a generally U configuration in cross section and includes upper and lower leg portions 32a and a central web portion 32b. As best seen in FIG. 3, plunger member 32 is sized to slide within the annular main body portion 24a of the housing with the arcuate upper and lower surfaces 32c of the legs 32a conforming to the annular housing surface 24j and with the upper and lower ends of the plunger member guiding on ridges 24k and 24m to maintain the plunger member in a generally upright configuration as seen in FIG. 3. Web portion 32b includes a central aperture 32d to pass the push rod 20 and upper and lower hub portions 32e. A transversely extending ridge 34f is provided on the inboard face of each leg portion 32a in forwardly spaced relation to web portion 32b. 
     Secondary plunger member 34 also has a generally U configuration in cross section and includes a partial side flange portion 34a, a full side flange portion 34b, and a central web portion 34c. Web portion 34c includes apertures 34d to pass the hub portions 32e of primary plunger member 32 and a central aperture 34e to pass the push rod 20. In the assembled relation of primary plunger member 32 and secondary plunger member 34, the secondary plunger member is interlinked with and carried by the primary plunger member with central aperture 34e aligned with central aperture 32d, apertures 34d receiving hub portions 32e of the primary plunger member, web portions 34c, 32b in confronting relation, and flanges 34a and 34b extending rearwardly and arms 32a extending forwardly. 
     Springs 26 comprise coil springs and are sized to be fitted around guide rod portions 24e. 
     Cruise control switch 27 includes a fixed contact 27a mounted on the inboard face 24n of housing rear end wall member 24c on one side of central axis 30 and a cantilever blade contact 27b mounted on inboard face 24n proximate fixed contact 27a. Cruise control switch 27 is normally spring biased to the open position seen in FIGS. 5, 6, 11, and 12 in which cantilever blade contact 27b is spaced from fixed blade contact 27a but is movable against the resistance of the spring bias to the closed position seen in FIGS. 4 and 10. 
     EFI switch 28 includes a fixed contact 28a mounted on inboard housing face 24n in diametrically opposed relation to fixed contact 27a and a cantilever blade contact 28b mounted on inboard face 24n proximate fixed contact 28a. EFI switch 28 is spring biased to the closed position seen in FIGS. 5, 6, 14, and 15 in which cantilever blade contact 28b contacts fixed contact 28a but is movable against the resistance of the spring bias to the open position seen in FIGS. 4 and 13. 
     Interlock switch contact strips 29 are mounted in axially extending disposition at diametrically opposed locations on housing interior cylindrical surface 24j proximate the front end of the housing. 
     In the assembled relation of the switch assembly and the master cylinder assembly, the switch is positioned in surrounding relation to push rod 20 rearwardly of the master cylinder. Specifically, housing hub portion 24g is received within the bore 16b defined at the rear end of the master cylinder rear end portion 16a; push rod 20 includes reduced diameter portion 20a passing through central aperture 24d in housing rear end wall member 24, aperture 32d in primary plunger member 32, aperture 34e in secondary plunger member 34, and aperture 24p in the housing front end wall member 24f for passage into the rear end of the hydraulic master cylinder for pivotal connection with piston 18; primary plunger member 32 is positioned within the hollow of the housing with hub portions 32e encircling guide rods 24e; springs 26 are positioned around guide portions 24e with their .forward ends bearing against the front wall of the housing and their rear ends received within hub portions 32e so as to bias the plunger member 32 toward the rear end of the housing; secondary plunger member 34 is mounted on and carried by primary plunger member 32; a ring 40 fixedly positioned on push rod reduced diameter portion 20a coacts with an annular forwardly facing surface 34f on the front face of the web portion of secondary plunger member 34; and an annular shoulder 20b formed at the juncture of reduced diameter push rod portion 20a and main body push rod portion 20c is arranged for pushing coaction with an annular rearwardly facing surface 32g on the primary plunger member 32 in surrounding relation to central aperture 32d. 
     It will be understood that a return spring 42 in cylinder 16 acts against piston 18 and normally maintains the push rod 20 in a fully rearwardly extended position (seen in FIG. 1) as determined by the engagement of the piston with a suitable stop member proximate the rear end of the master cylinder. With the push rod in its fully rearwardly extended position, and as seen in FIGS. 4, 7, 10 and 13, ring 40 bears against surface 34f on secondary plunger member 34 to press flange 34b rearwardly against the cantilever blade contact 27b of cruise control switch 27 and press flange 34a against the cantilever blade , contact 28b of EFI switch 28. Flange 34b has the effect of maintaining cruise control switch 27 in a closed position against the spring bias of the switch and flange 34a has the effect of maintaining EFI switch 28 in an open position against the spring bias of the switch. 
     When the control pedal 12 is depressed to actuate the associated motor vehicle control system, the first increment of forward movement of the push rod 20 has the effect of moving ring 40 incrementally forwardly to allow secondary plunger member 34 to move forwardly under the urging of the spring bias of the switches 27 and 28 so that the cruise control switch 27 is moved to an open position (as seen in FIG. 5) and the EFI contact switch is moved to a closed position (as seen in FIG. 14). The first increment of forward movement of the secondary plunger member 34 under the urging of the switches 27 and 28 comprises forward movement of plunger member 34 relative to plunger member 32 (which is held against forward movement by springs 26) and results in the front face of the secondary plunger member moving into contact with the ridges 32f on the arms 32a of the primary plunger member. As the push rod continues its forward movement, the plunger assembly 32,34 is maintained in its position proximate the rear wall of the housing by the springs 26 and the push rod moves forwardly relative to the plunger assembly until the shoulder 20b on the push rod encounters the rearwardly facing surface 32g on the web portion of the primary plunger member, whereafter continued incremental forward movement of the push rod moves the plunger assembly 32,34 forwardly within the housing to bring electrical contacts 44 on the arm portions 32a of the primary plunger member 32 into respective engagement with the contact strips 29 positioned on the cylindrical inner surface of the housing whereby to complete any interlock circuit to allow the starter motor of the motor vehicle to be energized. Contact between contacts 44 and 29 continues as the push rod continues its forward movement to complete the total disengagement of the associated motor vehicle control system such, for example, as the clutch so that the interlock circuit is completed and remains completed during the entirety of the last portion of the forward movement of the push rod. 
     When the control pedal 12 is released by the operator, spring 42 acts to move the push rod rearwardly to its fully rearwardly extended position. Specifically, during the first increment of rearward movement of the returning push rod, the plunger assembly moves rearwardly with the push rod under the urging of springs 26 until the plunger assembly reaches the position seen in FIG. 8, whereupon the push rod continues rearwardly relative to the plunger assembly, separating the push rod shoulder 20b from the surface 32g, until the ring 40 engages the surface 34f on the secondary plunger member, whereafter during the final increment of rearward movement of the push rod the secondary plunger member is moved rearwardly by an amount sufficient to overcome the spring bias of the switches 27 and 28 and move the cruise control switch into a closed position and the EFI switch into an open position, both against the spring bias of the respective switch. Ring 40 continues to maintain the switches in the respective Closed and open positions until such time as the control pedal 12 is again depressed to begin a new cycle of operation. 
     It will be understood that contacts 50 provided in the contact housing portion 24b are suitably connected electrically to the various switches and switch contacts 27, 28, 29, and 44 so that a single harness (not shown) may be plugged into the housing portion 24b to connect electrically with the cruise control, EFI, and interlock switches and generate appropriate control signals for transmission to the appropriate vehicle control systems upon actuation of the cruise control, EFI, and interlock switches upon forward stroking movement of the push rod. 
     Although the master cylinder switch seen in FIGS. 1-17 has a total circular configuration so that it must be inserted axially over the push rod, there are many applications where it is preferable to mount the switch onto the push rod by a lateral movement of the switch relative to the push rod. A side mounting arrangement of this type is shown in FIGS. 18 and 19. 
     The master cylinder switch of FIGS. 18 and 19 is identical to the switch of FIGS. 1-17 in all respects except that a slot is provided in the assembly to allow the assembly to be mounted with a lateral movement onto the push rod. Specifically, the main body annular portion 24a of the housing includes a flat side wall portion 24r defining a longitudinal slot 24s; the front end wall member defines a laterally extending slot 24t opening in aperture 24p; the rear end wall member 24c defines a laterally extending slot 24u opening in central aperture 24d; primary plunger 32 defines a laterally extending slot 32g opening in central aperture 32d; and the secondary plunger 34 defines a laterally extending slot 34g opening in central aperture 34e. It will be seen that slots 24s, 24t, 24u, 32g, and 34g coact to allow the switch to be mounted onto push rod 20 with a lateral movement of the switch relative to the push rod so as to position the push rod within apertures 34e, 32d, 24d and 24p, whereafter a cover 50 may be installed to preclude inadvertent displacement of the switch from the push rod. The slots 24t, 24u, 32g and 34g preferably define necked down throat areas (for example throat area 32h) at their juncture with the respective central aperture so that the switch moves into position over the push rod with a snap action. 
     Cover 50 may for example include a front leg portion 50a sized to fit in slot 24t and terminating in an inboard arcuate surface 50b for coaction with aperture 24p; a rear leg portion 50c sized to fit in slot 24u and terminating in an inboard arcuate surface 50d for coaction with aperture 24d; a main body portion 50d sized to be received in slot 24s; and a mounting flange portion 50e adapted-to be positioned against the flat side surface 24r of the housing and including means (not shown) to detachably secure the flange plate, and thereby the cover, to the housing. The operation of the switch embodiment of FIGS. 18 and 19 is identical to the operation of the switch embodiment of FIGS. 1-17. 
     It will be seen that the invention switch, by virtue of the lost motion between the push rod and the plunger assembly, allows a relatively short switch to be utilized in conjunction with the push rod without sacrificing the necessity of the push rod to move a predetermined distance between the actuation of the Various switches, thereby enabling the invention switch to be utilized on even very short push rods, that is, push rods that are too short to accommodate prior art switches of the type shown in the previously identified prior art patents. 
     Further, the invention switch may be made with a relatively small outside diameter, small enough to pass through the existing master cylinder mounting hole in the firewall of the vehicle, so that the master cylinder, push rod, and switch may be installed as an assembly by passing the assembly through the firewall opening from the engine side of the firewall. 
     Whereas preferred embodiments of the invention has been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the scope or spirit of the invention.