Input control module with adaptive actuators

An electronic input control assembly adjusts to the shape of a receiving assembly. The input control assembly includes an input control module and an actuator module. The actuator module has one or more actuators that are manually activated by a user. Advantageously, the input control module and the actuator module are moveably attached in a manner allowing relative motion which facilitates alignment when the input control assembly is placed within a receiving assembly. A garage door opener utilizes this adjustable design. A method of assembly the input control assembly is described.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to electronic control assemblies with adjustable positioning of sub-components of the control assemblies, and in particular, to garage door open systems using such electronic control assemblies.

2. Background Art

The associated costs of electronically controlled systems, and in particular, electronically controlled systems in automobiles provides an ever increasing impetus to find cost reducing strategies. Increasing complexity of such electronically controlled systems along with a desire to integrate such components into a vehicle in an aesthetically pleasing manner adds to the costs of such systems. Garage door openers are one example of such electronically controlled systems.

In addition to the costs of the components of such electronic systems, there is also an increase cost associated with the fabrication and assembly of these electronically controlled systems. Since these systems typically include several sub-assemblies that must be put together, physical tolerances of the components become an issue with misalignment being multiplied as the components are assembled. In the case of systems that use switch modules that are manually operated by a user, these misalignments are often associated with sticking or jammed buttons and switches. Garage door openers are an example of such a system using a switch module.

Accordingly, there exists a need for improved electronic control systems that are easily assembled and have flexibility with respect to the physical tolerances of any sub-assemblies and components.

SUMMARY OF THE INVENTION

The present invention solves one or more problems of the prior art by providing in at least one embodiment, an electronic input control assembly that adjusts to the shape of a receiving assembly. The input control assembly of the invention comprises an input control module and an actuator module. The actuator module includes one or more actuators that are manually activated by a user. Advantageously, the input control module and the actuator module are moveably attached in a manner allowing relative motion. The relative positionability of the input control module to the actuator module facilitates alignment with a receiving assembly that includes mounting or bezel openings.

In another embodiment of the invention, a method for assembling an electronic control device such as a garage door opener is provided. The method of this embodiment comprises attaching an input control module to an actuator module. The input control module includes first connectors while the actuator module includes second connectors that are connected to the first connectors such that the input control module is moveable relative to the actuator module. The thus formed control assembly is positioned within a receiving assembly. The relative positions of the input control module and the actuator modules are adjusted such that the control assembly is aligned with the shape receiving assembly without any buttons of the actuator module sticking to the receiving assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Reference will now be made in detail to presently preferred compositions or embodiments and methods of the invention, which constitute the best modes of practicing the invention presently known to the inventors.

As used herein, the term “input control module” means an electronic device containing an input device that allows a person to enter data into or control another device. Typically, such input devices are switches that are actuated by a user. Input control modules are used in any electronically controlled or operated device or system (e.g., a garage door openers, keyless entry systems, keyboards, and the like).

As used herein, the term “actuator module” means a module that includes the physical devices manually operated by a user operating the input control module. Typically, such actuator modules include buttons or switches that are activated by the users. The actuator module includes one or more physical structures (i.e., actuators) that transfer the user input to the input control module.

In one embodiment of the present invention, an electronic input control assembly attachable to a receiving assembly is provided. With reference toFIGS. 1A,1B, and1C, schematics of the electronic input control assembly of the present invention is provided.FIG. 1Ais an idealized cross-section of the input control assembly which includes an input control module and an actuator module.FIG. 1Bshows an idealized section of the actuator module.FIG. 1Cis a side view of the actuator module. Input control assembly10includes input control module12having side14that defines one or more first connectors16,18. In one variation of the present embodiment, first connectors16,18are slots of various configurations. Input control assembly10also includes actuator module20. Actuator module20includes one or more second connectors22,24which are used to attach actuator module20to input control module12. Typically, second connectors22,24are barbed extensions having extension section26and barb section28.

Still referring toFIGS. 1A,1B, and1C, attachment of input control module12to actuator module20is accomplished by positioning second connectors22,24within first connectors16,18such that input control module12is moveable relative to the actuator module20allowing adjustment of the relative positions of input control module12and actuator module20. This relative moveablity allows control assembly10to adjust to the shape of the receiving assembly30. In a variation of this embodiment, second connectors22,24are moveable within first connectors16,18along two orthogonal directions d1and d2. Although the extent of the motion along directions d1and d2are of any amount compatible with the sizes of the components, typically second connectors22,24are moveable within first connectors16,18over a distance of about 0.25 inches or less along each of the two orthogonal directions. Adjustability over this distance scale provides sufficient adjustability to allow input control assembly to align to the shape of receiving assembly30. It should be appreciated that in the most general implementation of the invention, the term first and second connectors merely means a mated pair of structures that fit together for the purposes of connecting input control module12to actuator module20. Accordingly, any specific implementation of the first and second connectors may be switched.

Input control module12also includes electronic device40which includes one or more electronic components42that are activated by actuator module20. In a variation of the present embodiment, electronic device40comprises an electronic circuit board and electronic components42are switches (e.g., tact switches). Input control module12also includes attachment section44which are utilized to attach input control assembly10to receiving assembly30. Examples of such receiving assemblies include vehicle bezel or trim components.

In a variation of the present embodiment, actuator module20includes at least one button(s)50with attached actuator shaft(s)52. In this variation, actuator20is a switch module. When button50is manually activated by a user, actuator shaft52engages electronic component42thereby initiating the pre-designed action of input control module12associated with electronic component42's activation (or deactivation). In one particularly important variation, input module12is part of a garage door opener system, and in particular, a transmitter for a garage door opener system which is integrated into the passenger compartment of an automobile. In a variation of the present embodiment, receiving assembly30includes a mounting plate having openings52into which button50protrudes. It is readily appreciated that it is the relative moveability of input control module12and actuator module20that allows for button(s)50to properly fit into openings52without sticking.

In another embodiment of the present invention, a garage door opener utilizing the design of the input control assembly10set forth above is provided. The garage door opener of this embodiment is advantageously incorporated into the overhead console of a vehicle interior. With reference toFIGS. 2 and 3, views of the garage door opener of the invention are provided.FIG. 2is a perspective view of the garage door opener of this embodiment. Garage door opener transmitter60includes input control module62and actuator module64. Actuator module64includes connectors66,68which fit into slots70,72of input control module62. As set forth above, slots70,72are somewhat oversized thereby allowing connectors66,68to be moveable when they are positioned within slots70,72. Garage door opener transmitter60attaches to a receiving assembly via attachment sections86. Actuator module84is optionally covered with soft touch layer88which is held in position via pegs90. Actuator module64includes buttons92,94,96. Typically, actuator module84is a switch module.

With reference toFIGS. 2,3,4and5, schematics illustrating components of garage door opener transmitter60are provided.FIG. 4is a perspective view of the bottom side of actuator module64.FIG. 5is a perspective view of an encasement of input control module62with actuator module64attached thereto. Actuator module64, as illustrated, is a switch module that includes buttons92,94,96. Actuator shafts100,102,104are attached to a bottom side of buttons92,94,96. It is actuator shafts100,102,104that contact switches in input control module62upon operation of buttons92,94,96by a user. In a variation of the present embodiment, operation of buttons92,94,96will initiate the opening and closing of a garage door. Input control module62includes encasement110which includes encasement section112and encasement section114. Encasement section112and encasement section114are closed along hinge section116to form closed encasement118. An electronic device such as a printed circuit board is positioned with encasement118. The electronic device includes one or more switches that are activated by buttons92,94,96and actuator shafts100,102,104as set forth above.

In another embodiment of the present invention, a method for assembling an electronic control device is provided. With reference toFIGS. 1A,1B, and1C, input control assembly10is assembled by attaching input control module12to actuator module20. Actuator module20is attached to the input control module12by positioning second connectors22,24within first connectors16,18such input control module12is moveable relative to actuator module20due to moveability of second connectors22,24relative to first connectors16,18. Input control assembly10is then positioned within receiving assembly30. Receiving assembly30is adapted to receive input control assembly10and includes a mating region having a shape that conforms to at least a portion of the input control assembly10within predetermined tolerances. Utilizing the relative moveablity between input control module12and actuator module20, the relative position of input control module12and actuator module20is adjusted such that the control assembly is aligned with the shape of the mating region.

The details of input control assembly10are set forth above. In particular, the position adjustment of the present embodiment is accomplished by the relative movement of second connectors22,24with first connectors16,18along the two orthogonal directions d1and d2. In a variation, second connectors22,24are moveable within first connectors16,18over a distance of about 0.25 inches or less along each of the two orthogonal directions.