Abstract:
A starter assembly for a vehicle includes a housing adapted to be coupled to a vehicle ignition system. A carrier has a key opening and is movably mounted within the housing. A latch is movably mounted to the carrier and is movable between a first latch position and a second latch position. An electronic key is provided to be received in the key opening of the carrier. The key has a first end, a second end, and a longitudinal axis. The first end includes a first end wall. The first end wall has an opening defining an axially extending cavity therein.

Description:
BACKGROUND 
     Various embodiments of a starter assembly are described herein. In particular, the embodiments described herein relate to an improved starter assembly for starting a vehicle with an electronic key. 
     Devices for starting a motor vehicle with an electronic key are well known. One known device is disclosed in U.S. Pat. No. 6,776,016 to Wittwer et al. and includes a key inserted in a slot in a housing. The key can be displaced to various key positions corresponding to different control functions of the motor vehicle. The key ( 50 ) is force-fit in the slot in a first position. In a second position, the key ( 50 ) is secured by a lock assembly in an automatically locking positive fit. The key ( 50 ) is then pushed to a third final position in which the lock assembly on the key can be released. In the second position, retaining arms ( 21 ) are disposed within grooves or notches ( 42 ) formed in an outer surface of the key ( 50 ). The vehicle may be started by a push-button actuator ( 35 ) provided in the device housing. 
     European Patent No. EP 1 419 944 discloses starter lock system having a push-push mechanism for inserting, retaining, and removing the key ( 2 ) in the housing ( 4 ). The key ( 2 ) is retained by a lever ( 20 ) urged into a recess ( 23 ) formed in an outer surface of the key ( 2 ). 
     SUMMARY 
     The present application describes various embodiments of a starter assembly. One embodiment of the starter assembly includes a housing adapted to be coupled to a vehicle ignition system. A carrier has a key opening and is movably mounted within the housing. A latch is movably mounted to the carrier and is movable between a first latch position and a second latch position. An electronic key is provided to be received in the key opening of the carrier. The key has a first end, a second end, and a longitudinal axis. The first end includes a first end wall. The first end wall has an opening defining an axially extending cavity therein. 
     Advantages of the starter assembly will become apparent to those skilled in the art from the following detailed description, when read in light of the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first embodiment of the vehicle starter assembly. 
         FIG. 2  is a sectional top elevational view of the vehicle starter assembly taken along the line  2 - 2  in  FIG. 1  and showing the key in the initial insertion position. 
         FIG. 3  is a sectional side elevational view of the vehicle starter assembly taken along the line  3 - 3  in  FIG. 1  and showing the key in the initial insertion position. 
         FIG. 4  is a sectional top elevational view of the vehicle starter assembly taken along the line  2 - 2  in  FIG. 1  and showing the key in the second insertion position. 
         FIG. 5  is a sectional side elevational view of the vehicle starter assembly taken along the line  3 - 3  in  FIG. 1  and showing the key in the second insertion position. 
         FIG. 6  is a sectional top elevational view of the vehicle starter assembly taken along the line  2 - 2  in  FIG. 1  and showing the key in the third insertion position. 
         FIG. 7  is a sectional top elevational view of the vehicle starter assembly taken along the line  2 - 2  in  FIG. 1  and showing the key in the fourth insertion position. 
         FIG. 8  is a sectional top elevational view of the vehicle starter assembly taken along the line  2 - 2  in  FIG. 1  and showing the key in the fifth insertion position. 
         FIG. 9  is a sectional top elevational view of a second embodiment of the vehicle starter assembly illustrated in  FIG. 1  and showing the key in the initial insertion position. 
         FIG. 10  is a sectional top elevational view of the vehicle starter assembly illustrated in  FIG. 9  and showing the key in the second insertion position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, and to  FIG. 1  in particular, a vehicle starter assembly is shown generally at  10 . The illustrated vehicle starter assembly  10  includes a housing  12  and an electronic ignition key fob or electronic key  14 . The illustrated electronic key  14  includes a key body  15  having first end  15 A, a second end  15 B and a longitudinal axis A. The electronic key  14  may include a radio frequency (RF) transponder (not shown) mounted within the key body  15 . The signal generated by the RF transponder may be read by a radio frequency (RF) coil mounted on a printed circuit board  70  in the housing  12 , described in detail below. 
     In the illustrated embodiment, the housing  12  is structured and configured to be coupled to a vehicle ignition system (not shown). The housing  12  may include a first housing portion  12 A (to the left when viewing  FIG. 2 ) and a second housing portion  12 B (to the right when viewing  FIG. 2 ). It will be understood the housing  12  may alternatively comprise a single piece or may be an assembly comprising two or more component pieces. It will be further understood that the key  14  may have any desired external shape and size other than shown in the exemplary embodiments illustrated in the figures. The housing  12  may also have any desired external shape and size other than shown in the exemplary embodiments illustrated in the figures. 
     Referring now to  FIG. 2 , the key  14  further includes a first end wall  16  having an opening  18 . The illustrated opening  18  defines access to an axially extending cavity  20  in the first end  15 A of the key  14 . 
     The first housing portion  12 A includes an opening  22  formed in a first end thereof. A pair of doors  24  (illustrated in an open position in  FIG. 2 ) are pivotally mounted in the housing  12  adjacent the opening  22  about pivot points  13 . A pair of first springs (not shown) urges the doors  24  into a closed position as shown by the phantom line  24 ′ in  FIG. 2 . 
     A frame  26  is mounted within the housing  12  and includes a first end  26 A having an opening  28  and a second or closed end  26 B. In the embodiment illustrated in  FIG. 2 , the frame  26  includes a first wall  30  opposite a second wall  32 . A first groove or recess  33 , a second groove or recess  34 , and a third, elongated groove or recess  35  are respectively formed in an inner surface of the first and second walls  30  and  32  at the closed end  26 B of the frame  26 . The first wall  30  includes a tapered portion  36  defining a camming surface intermediate the first end  26 A and the first recess  33  of the frame  26 . 
     In the illustrated embodiment, a carrier  38  in mounted for sliding movement within the frame  26 . The illustrated carrier  38  includes a first end  38 A and a second end  38 B. The first end  38 A includes wall surfaces  40  defining an opening  42  for receiving the electronic key  14 . The wall surfaces  40  define support surfaces for the key  14 . A detent channel  44  is formed in the second end  38 B of the carrier  38 . A pair of detent pins or plungers  46  are disposed in the channel  44  and biased outwardly by a second spring  48 . It will be understood that the plungers  46  may have any desired shape, such as for example, substantially spherical. 
     A latch  50  is pivotally mounted within the carrier  38  by a pin  52 . The latch  50  includes a latch body  54 , a radially outwardly extending latch arm  56 , and a cam member  58 . In the illustrated embodiment, a distal end of the latch arm  56  includes a lip  60  extending transversely to an axis of the latch arm  56 . As best shown in  FIGS. 3 and 5 , a latch boss  62  extends outwardly (upwardly as viewed in  FIGS. 3 and 5 ) of the latch body  54 . A third spring (not shown) is disposed between the latch  50  and the carrier  38  and urges the latch  50  into a first or unlatched position as illustrated in  FIGS. 2 and 3 . 
     In the embodiments illustrated in  FIGS. 1 through 8 , a latch release plunger  64  is mounted within the carrier  38 . The plunger  64  is substantially “L” shaped in section, and includes a first portion  64 A and a second portion  64 B. A fourth spring  66  is disposed between the plunger  64  and the second end  38 B of the carrier  38  and urges the plunger  64  away (to the left as viewed in  FIGS. 3 and 5 ) from the second end  38 B of the carrier  38 . 
     A pair of fifth springs  68  is disposed between an outside surface of the second end  38 B of the carrier  38  and the frame  26 , and urges the carrier  38  away (to the left as viewed in  FIGS. 2 and 3 ) from the second end  26 B of the frame  26 . 
     As best shown in  FIG. 3 , the latch boss  62  engages the plunger  64 , thereby preventing the latch  50  from pivoting about the pin  52  and retaining the latch  50  in the unlatched position illustrated in  FIG. 3 . In the unlatched position as best shown in  FIG. 2 , the cam member  58  engages the tapered portion  36  of the first wall  30  of the frame  26 , and the carrier  38  is urged toward the first end  26 A of the frame  26  by the force of the springs  68 . 
     In the embodiment illustrated in  FIG. 2 , the printed circuit board (PCB)  70  is disposed between the frame  26  and the housing  12 . The PCB  70  may include any desired electronic components, such as, for example, an LED (not shown), a plurality of micro-switches (not shown), an electrical connector (not shown) for connecting the PCB  70  to a source of power (not shown), and an RF coil (not shown). 
     In operation, the vehicle starter assembly  10  may be moved through a plurality of operational positions. Although five operational positions are described herein below, it will be understood that the starter assembly  10  may be structured and configured to move through any desired number of operational positions. 
     A vehicle operator may first insert the key  14  into the opening  22  of the housing  12  into a first insertion position, as shown in  FIGS. 2 and 3 . As the key  14  is inserted into the opening  22 , the doors  24  are moved from the closed position  24 ′ to the open position, as shown in  FIG. 2 . In the first insertion position, the first end  15 A of the key  14  is inserted into the housing  12  (to the right as viewed in  FIGS. 2 and 3 ) until the first end  15 A of the key  14  engages the first portion  64 A of the latch release plunger  64 . In the first insertion position, the latch  50  is in the unlatched position, and the plungers  46  are urged outwardly of the carrier  38  and are seated within the first recesses  33  of the frame  26 . 
     The vehicle operator may then apply a force in the direction of the arrow  82  (to the right as viewed in  FIGS. 4 and 5 ) on the key  14  to move the key  14  into a second insertion position, as shown in  FIGS. 4 and 5 . In the second insertion position, the force applied to the key  14  urges the plunger  64  against the force of the fourth spring  66  and toward the second end  38 B of the carrier  38 , as best shown in  FIG. 5 . The latch boss  62  thereby becomes disengaged from the second portion  64 B of the plunger  64 , and the arm  56  of the latch  50  is moved to a position within the cavity  20  of the key  14 . 
     The vehicle operator may then apply an additional force in the direction of the arrow  82  (to the right as viewed in  FIG. 6 ) on the key  14  to move the key  14  into a third insertion position, as shown in  FIG. 6 . In the third insertion position, the force applied to the key  14  urges the carrier  38  against the force of the pair of fifth springs  68  and toward the second end  26 B of the frame  26 , until the plungers  46  of the carrier  38  are seated within the second recesses  34  of the frame  26 . In the illustrated embodiment, the cam member  58  of the latch  50  is caused to slide along the tapered portion  36  of the first wall  30  of the frame  26 , thereby causing the latch  50  to pivot about the pin  52 , in the direction of the arrow  80 , and thereby move from the unlatched position, as shown in  FIGS. 2 through 5 , to the latched position, as shown in  FIG. 6 . 
     In the latched position illustrated in  FIG. 6 , the latch arm  56  moves (in a counterclockwise direction as viewed in  FIG. 6 ) within the opening  18  until the arm  56  engages a portion of the surface of the opening  18 . In the illustrated latched position, the key  14  is prevented from falling out of the housing (or moving to the left as viewed in  FIG. 6 ) by the lip  60  engaging the first end wall  16  adjacent the opening  18  in the first end  15 A of the key body  15 . In the third insertion position, a signal from the RF transponder in the key  14  may be read by the RF coil on the PCB  70 , indicating that the key  14  is in a position commonly referred to as the auxiliary position. 
     The vehicle operator may then continue to move the key  14  in the direction of the arrow  82  into a fourth insertion position, such that the vehicle starter assembly  10  is in the ignition position, as illustrated in  FIG. 7 . In the ignition position, the carrier  38  is urged toward the closed end  26 B of the frame  26  until the detent plungers  46  are urged outward of the carrier  38  and into first ends of the elongated third recesses  35  (the left ends of the recesses  35  when viewing  FIG. 7 ). In the fourth insertion position, a signal from the RF transponder in the key  14  may be read by the RF coil on the PCB  70 , indicating that the key  14  is in a position commonly referred to as the ignition or run position. 
     To start the vehicle, the vehicle operator may then continue to move the key  14  in the direction of the arrow  82  into a fifth insertion position such that the vehicle starter assembly  10  is moved to the crank or start position as illustrated in  FIG. 8 . In moving toward the crank position, the carrier  38  is urged further toward the closed end  26 B of the frame  26  and the detent plungers  46  slide along the elongated recesses  35  to the second ends of the elongated recesses  35  (the right ends of the recesses  35  when viewing  FIG. 8 ). In the fifth insertion position, a signal from the RF transponder in the key  14  may be read by the RF coil on the PCB  70 , indicating that the key  14  is in a position commonly referred to as the crank or start position. When the operator removes the force applied to the key  14 , the springs  68  urge the carrier  38  back to the ignition position as shown in  FIG. 7 . 
     To remove the key  14 , the vehicle operator may apply a force to move the key  14  outward of the housing  12  (to the left when viewing  FIG. 7 ) and through the auxiliary position illustrated in  FIG. 6 , the second insertion position illustrated in  FIGS. 4 and 5 , and the first insertion position illustrated in  FIGS. 2 and 3 . 
     Referring now to  FIG. 9 , a second embodiment of a vehicle starter assembly is shown generally at  100 . The illustrated vehicle starter assembly  100  is shown in the first insertion position and includes a housing  112  and an electronic key  114 . The illustrated electronic key  114  includes a key body  115  having first end  115 A, a second end (not shown) and a longitudinal axis AA. The electronic key  114  may include an RF transponder (not shown) mounted within the key body  115 . 
     In the illustrated embodiment, the housing  112  is structured and configured to be coupled to a vehicle ignition system (not shown). It will be understood the housing  112  may comprise a single piece or may be an assembly comprising two or more component pieces. It will be further understood that the key  114  may have any desired external shape and size other than shown in the exemplary embodiments illustrated in the figures. The housing  112  may also have any desired external shape and size other than shown in the exemplary embodiments illustrated in the figures. 
     The illustrated key  114  further includes a first end wall  116  having an opening  118 . The illustrated opening  118  defines access to an axially extending cavity  120  in the first end  115 A of the key  114 . 
     The housing  112  includes an opening  122  formed in a first end  112 A thereof. A door  124  (illustrated in a closed position in  FIG. 9 ) is slidably mounted in the housing  112  adjacent the opening  122 . Springs  113  and  119  urge the door  124  into the closed position (to the left as viewed in  FIG. 9 ) as shown in  FIG. 9 . The door  124  includes an opening  125  having at least one first ramped surface  127 , the purpose for which will be described in detail herein below. 
     A frame  126  is mounted within the housing  112 , and includes a first end  126 A having an opening  128 , and a second or closed end (not shown). In the embodiment illustrated in  FIG. 9 , the frame  126  includes a first wall  130  opposite a second wall  132 . A latch aperture  133  is formed in the first wall  130 . 
     In the illustrated embodiment, a carrier  133  is mounted for sliding movement within the frame  126 . The illustrated carrier  138  includes a first end  138 A and a second end  138 B. The first end  38 A includes wall surfaces  140  for receiving the electronic key  114 . The wall surfaces  140  define support surfaces for the key  114 . A detent channel  144  is formed in the second end  138 B of the carrier  138 . A detent member or ball  146  is disposed in the channel  144  and biased outwardly by a second spring  148 . Although the detent member  146  is illustrated as spherical in shape, it will be understood that the detent member  146  may have any desired shape, such as for example, the shape of the plungers  46  illustrated in  FIGS. 4 ,  6 ,  7 , and  8 . 
     A latch  150  is slidingly mounted within the carrier  138 . The latch  150  includes a latch body  154  and an outwardly (to the left as viewed in  FIG. 9 ) extending latch arm  156 . In the illustrated embodiment, a distal end of the latch arm  156  includes a second ramped surface  160 . A third spring  161  is disposed between the latch  150  and the carrier  138  and urges the latch  150  into a first or latched position within the latch aperture  133  (upwardly as viewed in  FIG. 9 ). 
     In operation, the second embodiment of the vehicle starter assembly  100  may be moved through the plurality of operational positions described herein above. It will be understood that the starter assembly  100  may be structured and configured to move through any desired number of operational positions. 
     A vehicle operator may first insert the key  114  into the opening  122  of the housing  112  into a first insertion position, as shown in  FIG. 9 . In the first insertion position, the first end  115 A of the key  114  is inserted into the housing  112  (to the right as viewed in  FIG. 9 ) until the first end wall  116  of the key  114  engages the door  124  and the wall surface  140 . In the first insertion position, the latch body  154  is urged into the aperture  133  and the latched position. 
     The vehicle operator may then apply a force in the direction of the arrow  180  (to the right as viewed in  FIG. 10 ) on the key  114  to move the key  114  into a second insertion position, as shown in  FIG. 10 . In the second insertion position, the force applied to the key  114  urges the door  124  against the force of the springs  113  and  119  and toward the second end  138 B of the carrier  138 , as best shown in  FIG. 10 . In the illustrated embodiment, the first ramped surface  127  engages the second ramped surface  160  as the door  124  moves toward the second end  138 B. The engagement of the first ramped surface  127  against the second ramped surface  160  causes the latch  150  to slide away from the frame  126  (downwardly as viewed in  FIG. 10 ). The latch  150  thereby becomes disengaged from the aperture  133 . 
     The vehicle operator may then apply an additional force in the direction of the arrow  180  (to the right as viewed in  FIG. 10 ) on the key  114  to move the key  114  into third and subsequent insertion positions, as described herein above. In the third and subsequent insertion positions, the ball  146  of the carrier  138  may become seated within recesses (not shown) of the frame  126 . 
     The principle and mode of operation of the vehicle starter assembly have been described in its various embodiments. However, it should be noted that the starter assembly described herein may be practiced otherwise than as specifically illustrated and described without departing from its scope.