Patent Publication Number: US-2010107804-A1

Title: Fixed pedal assembly with multi-piece support bracket and captive pivot

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
     Not Applicable 
     REFERENCE TO MICROFICHE APPENDIX 
     Not Applicable 
     FIELD OF THE INVENTION 
     The field of the present invention generally relates to control pedals and, more particularly, to control pedals for motor vehicles. 
     BACKGROUND OF THE INVENTION 
     Control pedals are typically provided in a motor vehicle, such as an automobile, which are foot operated by the driver. Separate control pedals are provided for operating brakes and an engine throttle. When the motor vehicle has a manual transmission, a third control pedal is provided for operating a transmission clutch. 
     Control pedal assemblies typically include a mounting bracket and a pedal arm pivotably attached to the mounting bracket. The pedal arm typically has a foot plate or pedal pad at a lower end and a bushing holder or hub at an upper end. A pivot pin is placed through the hub and the mounting bracket so that the pedal arm is pivotable relative to the mounting bracket when an operator presses the foot plate. The pivot pin must be spun or provided with a retainer to secure the pivot pin in position. The pedal arm is also provided with a suitable output connector so that the movement of the pedal operates the device to be controlled, such as a brake master cylinder, engine throttle or transmission clutch, in a desired manner. 
     While these prior art pedal assemblies may operate adequately operate, there is a never ending desire in the motor vehicle industry to reduce cost while maintaining or improving reliability. Accordingly, there is a need in the art for an improved pedal assembly which is relatively simple and inexpensive to produce and is highly reliable to operate. 
     SUMMARY OF THE INVENTION 
     The present invention provides a pedal assembly which overcomes at least some of the above-noted problems of the related art. According a disclosed embodiment of the present invention, a pedal assembly comprises, in combination, a mounting bracket and a pedal arm having a lower end carrying a pedal and an upper end having a pivot forming a laterally disposed pivot axis. The mounting bracket includes first and second lateral components formed as separate components and secured together to laterally capture the pivot therebetween such that the first and second components support the pivot and the pedal arm is pivotable about the pivot axis relative to the mounting bracket. 
     According to another disclosed embodiment of the present invention, a pedal assembly comprises, in combination, a fixed position mounting bracket and a pedal arm having a lower end carrying a pedal and an upper end having a pivot forming a laterally disposed pivot axis. The mounting bracket includes first and second lateral components which are formed as separate components and secured together to laterally capture the pivot therebetween such that the first and second components support the pivot and the pedal arm is pivotable about the pivot axis relative to the mounting bracket. The first and second components each form a laterally inward facing socket for receiving opposed ends of the pivot therein. 
     According to yet another disclosed embodiment of the present invention, a pedal assembly comprises, in combination, a mounting bracket and a pedal arm having a lower end carrying a pedal and an upper end having a pivot forming a laterally disposed pivot axis. The mounting bracket includes first and second lateral components which are formed as separate components and secured together to laterally capture the pivot therebetween such that the first and second components support the pivot and the pedal arm is pivotable about the pivot axis relative to the mounting bracket. The first and second components are each preferably molded of plastic and each form a laterally inward facing socket for receiving opposed ends of the pivot therein. The laterally outward end of each socket is at least partially closed and a spring member is located in one the sockets to resist lateral movement of the pedal arm relative to the mounting bracket. 
     From the foregoing disclosure and the following more detailed description of various preferred embodiments it will be apparent to those skilled in the art that the present invention provides a significant advance in the technology and art of control pedal assemblies. Particularly significant in this regard is the potential the invention affords for providing a reliable and low cost assembly. Additional features and advantages of various preferred embodiments will be better understood in view of the detailed description provided below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and further features of the present invention will be apparent with reference to the following description and drawings, wherein: 
         FIG. 1  is a perspective view of a control pedal assembly according to the present invention; 
         FIG. 2  is an exploded perspective view of the control pedal assembly of  FIG. 1 ; 
         FIG. 3  is a left side elevational view of the control pedal assembly of  FIGS. 1 and 2 ; 
         FIG. 4  is a rear elevational view of the control pedal assembly of  FIGS. 1 to 3 ; 
         FIG. 5  is a right-side elevational view of the control pedal assembly of  FIGS. 1 to 4 ; 
         FIG. 6  is a cross-sectional view taken along line  6 - 6  of  FIG. 3  showing a spring biased pivot; 
         FIG. 7  is a cross-sectional view taken along line  7 - 7  of  FIG. 3  showing a heat staked connection; and 
         FIG. 8  is a cross sectional view taken along line  8 - 8  of  FIG. 4  showing mounting holes with crush-limiters. 
     
    
    
     It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention. The specific design features of control pedal assemblies as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes of the various components, will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and clear understanding. In particular, thin features may be thickened, for example, for clarity or illustration. All references to direction and position, unless otherwise indicated, refer to the orientation of the adjustable control pedal assemblies illustrated in the drawings. In general, up or upward refers to an upward direction within the plane of the paper in  FIG. 1  and down or downward refers to a downward direction within the plane of the paper in  FIG. 1 . Also in general, fore or forward refers to a direction toward the front of the motor vehicle and aft or rearward refers to a direction toward the rear of the motor vehicle. 
     DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS 
     It will be apparent to those skilled in the art, that is, to those who have knowledge or experience in this area of technology, that many uses and design variations are possible for the improved control pedal assemblies disclosed herein. The following detailed discussion of various alternative and preferred embodiments will illustrate the general principles of the invention with reference to a brake pedal for use with a motor vehicle. Other embodiments suitable for other applications will be apparent to those skilled in the art given the benefit of this disclosure. While the illustrated pedal assembly is adapted as a brake pedal, it is noted that pedal assembly can alternatively be adapted as an accelerator, clutch, or other desired foot pedal within the scope of the present invention. Also, while the illustrated embodiments of the present invention are particularly adapted for use with an automobile, it is noted that the present invention can be utilized with any vehicle having at least one foot operated control pedal including trucks, buses, vans, recreational vehicles, earth moving equipment and the like, off road vehicles such as dune buggies and the like, air borne vehicles, and water borne vehicles. 
     Referring now to the drawings,  FIGS. 1 to 5  show a control pedal assembly  10  according to a preferred embodiment of the present invention. The illustrated control pedal assembly  10  includes a fixed position support or mounting bracket  12  and a pedal arm  14  having a lower end carrying a pad or pedal  16  for engagement by the foot of the motor vehicle operator and an upper end having a pivot  18  forming a laterally disposed pivot axis  20 . 
     The illustrated mounting bracket  12  includes first and second or left and right lateral portions or components  22 ,  24 . The left and right components  22 ,  24  are formed as separate components and are secured together to laterally capture the pivot  18  of the pedal arm  14  therebetween such that the left and right components  22 ,  24  support the pivot  18  and the pedal arm  14  is pivotable about the pivot axis  20  relative to the mounting bracket  12 . The illustrated left and right components  22 ,  24  are molded of a plastic material but alternatively can be formed in any other suitable manner and/or of any other suitable material. 
     The illustrated left and right components  22 ,  24  have a vertically disposed and laterally facing connection or separation plane such that the pivot axis  20  is substantially perpendicular to the separation plane. The illustrated left and right components  22 ,  24  are generally equally sized such that the separation plane is centrally located in the lateral direction but is noted that the components  22 ,  24  can be sized in any other suitable manner. The left and right components  22 ,  24  preferably interlock in the forward rearward direction. The illustrated left and right components  22 ,  24  have a plurality of laterally disposed posts  26  and cooperating openings  28  for receiving the posts  26 . The illustrated components  22 ,  24  have three posts  26  and three openings  28  but any other suitable quantity can alternatively be utilized. The illustrated posts  26  include a forward upper post  26   a , a rearward upper post  26   b , and a forward lower post  26   c.  The upper posts  26   a ,  26   b  are located on opposite sides of the pivot axis  20 . The illustrated posts  26  and openings  28  include cooperating laterally facing steps or abutments  30 ,  32  so that the posts  26  laterally engage the openings  28  (best shown in  FIG. 7 ). The illustrated posts  26  are heat staked to rigidly secure the left and right components  22 ,  24  together. The openings  28  extend entirely through the components  22 ,  24  in the lateral direction in order to provide access to the ends of the posts  28  for heat staking. It is noted that the left and right components  22 ,  24  can alternatively be secured together in any other suitable manner such as, for example, adhesives, bolts, rivets, or any other suitable manner. The illustrated left and right components  22 ,  24  also cooperate to form a rear flange  30  where the left component  22  has a pair of protrusions  32  which are received in slots  34  of the right component  24  when the left and right components  22 ,  24  are laterally brought together. The illustrated rear flange  30  forms a stop for the pedal arm  14  to define a full rearward or un-actuated position. The rear flange  30  can be provided with stopper pad or bumper if desired for engagement by the pedal arm  14 . The illustrated rear flange  30  is also provided with a mounting opening  36  for attachment of a switch to indicate when the pedal arm  14  is out of the un-actuated position. This information can be used for example to illuminate brake lights when the pedal arm  14  is depressed by the operator. It is noted that the front flange  30  provides a which bracket that is integral with the mounting bracket, that is, does not have to be separately formed and secured thereto. 
     The illustrated left and right components  22 ,  24  also form laterally inward facing sockets  38  for receiving the pivot  18  of the pedal arm  14  (best shown in  FIG. 6 ). The illustrated sockets  38  are blind, that is, they have closed laterally outward ends  40  so that the pivot  18  is captured between the left and right components  22 ,  24 . Note that the sockets  38  form laterally inward facing abutments for the pivot  18 . The illustrated sockets  38  are provided with cup-shaped bushings  42  preferably formed of a lower friction material and/or longer wearing material. For example, the bushings  42  can be formed of Nylon or the like. 
     The mounting bracket  12  is adapted to rigidly attach the adjustable control pedal assembly  10  to a firewall or other rigid structure of the motor vehicle at a fixed position. The illustrated left and right components  22 ,  24  also cooperate to form a front flange  44  having a plurality of mounting openings  46 . The illustrated front flange  44  has four mounting openings  46  but any other suitable quantity can alternatively be utilized. The illustrated the front flange  44  has portions  44 a,  44   b  formed by each of the left and right components  22 ,  24 . The portion  44   b  formed by the right component  24  overlaps the portion  44   a  formed by the left component  22  so that the portion  44   b  formed by the right component  24  forms at least a portion of each of the mounting openings  46 . This ensures the mounting openings  46  are located in the desired locations relative to one another. The mounting openings  46  are sized and shaped to receive mechanical fasteners for attaching the control pedal assembly  10  to the structure of the motor vehicle. The illustrated mounting openings  46  are provided with crush limiters  47  (best shown in  FIG. 8 ). The crush limiters  47  are preferably press fit into the left and right components  22 ,  24  before the left and right components  22 ,  24  are heat staked or otherwise secured together. The illustrated front flange  44  is also provided with an opening  48  for access to the pedal arm  14  as described in more detail hereinafter. The illustrated right side component  24  is also provided with an access opening  50  as described in more detail hereinafter. 
     The illustrated pedal arm  14  is generally elongate and formed of a bar having a generally rectangular cross-section. The pedal arm  14  carries the pedal  16  at its lower end. The pedal  16  is sized and shaped for engagement by the foot of the motor vehicle operator so that the operator can depress the pedal arm  14  to actuate a control device. The pedal  16  can be formed unitary with the pedal arm  14  as a one-piece component or can be formed as a separate component and rigidly secured thereto. The pedal can also be provided with a separate pad if desired. The upper end of the pedal arm  14  has the pivot  18  which forms the laterally disposed pivot axis  20 . The illustrated pivot  18  is in the form of a hub which in turn is in the form of a hollow tube having a circular cross-section (best shown in  FIG. 6 ). It is noted that the pivot  18  can alternatively have any other suitable form such as, for example, a solid pin. The illustrated pivot  18  extends laterally through an opening  52  near the upper end of the pedal arm  14  and is rigidly secured to the pedal arm  14  so that the opposed ends of the pivot  18  extend laterally outward from the pedal arm  14 . The illustrated pivot  18  is rigidly secured to the pedal arm  14  by mechanical deformation of the pivot  18  on each side of the pivot arm by means such as external upsetting of the material of the pivot at beads  54 . It is noted that the pivot  18  can alternatively be secured to the pedal arm  14  in any other suitable manner and/or alternatively can be formed unitary with the pedal arm  14  as a one piece component. The pedal arm  14 , the pedal  16 , and the pivot  18  can each be formed of any suitable material. 
     The opposite facing free ends of the pivot  18  are received into the sockets  38  of the left and right components  22 ,  24  as the left and right components  22 ,  24  are laterally brought together and secured together. With the ends of the pivot  18  in the sockets  38  and the left and right components  22 ,  24  secured together, the pivot  18  and the pedal arm  14  are captured between the components  22 ,  24 . As best shown in  FIG. 6 , the pivot  18  is located entirely between the left and right brackets  22 ,  24  and does not extend to or outward of the lateral sides of the left and right components  22 ,  24 . The mounting bracket  12  supports the pivot  18  and the pedal arm  14  only by engagement at the pivot  18 . Clearance space is provided at each lateral side of the pedal arm  14  between the pedal arm  14  and the mounting bracket  12 . Supported in this manner, the pedal arm  14  is pivotable relative to the fixed mounting bracket  12  about the horizontally and laterally extending pivot axis  20  formed by the pivot  18  when the vehicle operator depresses the pedal. 
     A spring member  56  is provided in at least one of the sockets  38  which acts on the pivot  18  to resiliently bias the pivot  18  and the pedal arm  14  in the lateral direction in order to reduce lash in the lateral direction, that is, undesired relative movement in the lateral direction between the pedal arm  14  and the mounting bracket  12 . The illustrated spring member  56  is in the form of a wave washer located between the bushing  42  and the blind end  40  of the right side socket  38 . It is noted that the spring member  56  can alternatively have any other suitable form such as, for example, a coil spring or a leaf spring and/or can alternatively be located at any other suitable location such as, for example, directly acting on the pivot  18 , acting on the pedal arm  14 , or at the left side socket  38 . 
     The pedal arm  14  is operatively connected to a control device such as a brake master cylinder so that pivotal movement of the pedal arm  14  about the pivot axis  20  operates the control device in a desired manner. The illustrated pedal arm  14  can be connected to the control device by a mechanical rod or cable for mechanical actuation of the control device. It is noted that the movement of the pedal arm  14  can alternatively be provided to the control device by a sensor and electrical wire, cable, or wireless connection for electronic actuation of the control device. The mechanical rod or cable can be secured to the pedal arm  14  at an opening  58  provided therein and extend through the opening  48  in the front flange  44  of the mounting bracket  12  to the control device. The illustrated opening is provided between the pedal  16  and the pivot  18 . The access opening  50  in the right component  24  of the mounting bracket  12  provides access to the pedal arm opening  52  (best shown in  FIG. 5 ) for connection of the rod or cable during installation of the control pedal assembly  10  to the motor vehicle. The control device and/or mechanical rod or cable preferably provides a rearward biasing return spring which resiliently biases the pedal arm  14  to its full rearward or un-actuated position against the stop. Alternatively, a separate return spring can be provided to resiliently bias the pedal arm  14  to its full rearward or u-actuated position against the stop. 
     To actuate the control device, the operator depresses the pedal  16  with a foot to forwardly pivot both the pedal arm  14  and the pivot  18  together about the pivot axis  20 . This forward pivotal movement of the pedal arm  14  pushes the mechanical rod or cable to actuate the control device in the desired manner. When the operator removes the pressure from the pedal  16 , the return spring automatically pivots the pedal arm  14  back to its full rearward or un-actuated position against the stop. 
     From the foregoing disclosure and detailed description of certain preferred embodiments, it is apparent that the illustrated control pedal assembly  10  eliminates the use of a through pivot pin that extends through openings in the mounting bracket and which must be secured in place by means such as spinning, deformation, fasteners, clips or other mechanical means. This eliminates an assembly step and reduces required assembly equipment. It is also apparent that the illustrated control pedal assembly  10  eliminates the need to weld or otherwise attach a switch bracket. This also eliminates an assembly step and reduces required assembly equipment. It is further apparent that the illustrated control pedal assembly  10  utilizes “pick and place assembly” to minimize assembly time and cost. 
     From the foregoing disclosure and detailed description of certain preferred embodiments, it is also apparent that various modifications, additions and other alternative embodiments are possible without departing from the true scope and spirit of the present invention. The embodiments discussed were chosen and described to provide the best illustration of the principles of the present invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present invention as determined by the appended claims when interpreted in accordance with the benefit to which they are fairly, legally, and equitably entitled.