Patent ID: 12202568

DETAILED DESCRIPTION

The present technology will be described with reference to a four-wheeled straddle-seat all-terrain vehicle (ATV)10. It is contemplated that the present technology may be used with other vehicles steered via a handlebar such as snowmobiles, motorcycles and three-wheeled on-road vehicles.

Referring toFIG.1, the ATV10has a frame12and a vehicle body14mounted to the frame12. The ATV10has two front wheels16and two rear wheels18connected to the frame12via corresponding suspension assemblies20(only a front left one of which is partially shown inFIG.1). Each of the four wheels16,18is provided with a low-pressure balloon tire adapted for off-road conditions. It is contemplated that the ATV10could have six wheels or only three wheels.

The ATV10has a straddle seat22connected to the frame12for accommodating a driver of the ATV10. A motor24, schematically shown inFIG.1, is connected to the frame12. The motor24drives the front and rear wheels16,18. It is contemplated that the motor could drive only the front wheels16or only the rear wheels18. In the present embodiment, the motor24is an internal combustion engine. It is contemplated that the motor24could be replaced by an electric motor or a hybrid propulsion unit (i.e. an internal combustion engine and an electric motor). The motor24is disposed under the straddle seat22. The wheels16,18are operatively connected to the motor24via a continuously variable transmission (CVT)26.

Footrests28are laterally provided on either side of the straddle seat22and are disposed vertically lower than the straddle seat22to support the driver's feet. The footrests28are connected to the frame12. A steering assembly, including a handlebar30, is rotationally connected the frame12. The handlebar30is connected to a steering column assembly (not shown) for actuating steering linkages (not shown) operatively connected to the front wheels16for steering the front wheels16. Hand grips32are disposed on the ends of the handlebar30.

A throttle operator34, in the form of a thumb-actuated throttle lever, is mounted to a right side of the handlebar30to control a speed of the motor24. Other types of throttle operators, such as a finger-actuated throttle lever and a twist grip, are also contemplated. A switch assembly36is mounted to the right side of the handlebar30near the right hand grip32. The switch assembly36has a number of switches for controlling various features and components of the ATV10. A brake lever38is mounted to a left side of the handlebar30. A switch assembly100is mounted to the left side of the handlebar30near the left hand grip32. The switch assembly100will be described in more detail below.

The ATV10has a winch40connected to the frame12at a front thereof. The winch40includes a winch motor (not shown), selectively driving a spool (not shown) around which a winch cable42is wound. The winch cable42passes through alignment rollers44. A hook46is connected to the end of the winch cable42. As will be described below, the winch40is an optional component of the ATV10and may not be provided in some embodiments of the ATV10.

The ATV10has headlights48and taillights (not shown). Front and rear cargo racks50are provided over the vehicle body14at the front and rear of the ATV10. The ATV10further includes other components such as brakes, a fuel tank, an air intake system and an exhaust system. As it is believed that these components would be readily recognized by one of ordinary skill in the art, further explanation and description of these components will not be provided herein.

Turning now toFIGS.2to7, the switch assembly100will be described in more detail. The switch assembly100has a main housing102having left104, right106, front108, rear110, top112and bottom114sides. As seen inFIG.7, the main housing102is made of a front housing portion116and a rear housing portion118that are connected each other by fasteners120. The front housing portion116defines a semi-circular channel122. Similarly, the rear housing portion118defines a semi-circular channel124. When the front housing portion116is connected to the rear housing portion118, the channels122,124define cylindrical passage126through which the handlebar30extends generally laterally to mount the main housing102to the handlebar30. It is contemplated that in alternative embodiments, the main housing102could be one integral component. It is also contemplated that the main housing102could be made of more than two portions.

The main housing102has a number of switches mounted thereto. A speed limiter ON/OFF switch128is mounted to the front housing portion116on the top side112of the main housing102. Speed limiter set and reset switches130(seeFIGS.4and6) are mounted to the front housing portion116on the front side108of the main housing102. The speed limiter ON/OFF switch128turns a vehicle speed limiting function of the ATV10, and the speed limiter set and reset switches130set and reset the speed associated with the speed limiting function respectively. A run and stop switch132is mounted to the rear housing portion118on the rear side110of the main housing102. The run and stop switch132has a run position and a stop position. The ATV10is not operable when the run and stop switch132is in the stop position. If the ATV10is to be operated, the run and stop switch132must be in the run position. A start and override switch134is mounted to the rear housing portion118on the rear side110of the main housing102. When the run and stop switch132is in the run position, the start and override switch134may be pushed to start the ATV10. In some operating conditions, such as when the ATV10is in reverse, the ATV10speed is limited. The driver may override this speed limit by pushing the start and override switch134. A headlight switch136is mounted to the rear housing portion118on the rear side110of the main housing102, above the run and stop switch132and to the left of the start and override switch134. The headlight switch136controls the headlights48of the ATV10between an off mode, a low-beam mode, a high beam mode. It is contemplated that the above switches could be disposed differently than illustrated, that some of these switches may be omitted and that other switches controlling other aspects of the ATV10could be mounted to the main housing102.

The switches mounted to the main housing102are connected to a cable138(FIGS.2and3) that communicates signals from the switches to a control unit (not shown) of the ATV10. One end of the cable138is disposed inside the main housing102, the cable138exits the main housing102via a grommet (not shown) provided on the rear housing portion118, on the lower right side106of the main housing102, and the portion of the cable138exiting the main housing102is fastened to a tab139by a tie-wrap140.

With reference toFIGS.5and7, it can be seen that the main housing102defines a recess142. More specifically, the recess142is defined in the rear housing portion118at the rear, right corner of the main housing102, below the start and override switch134. As such, the recess142has a front wall144, a left wall146, a top wall148and a bottom wall150and the recess142opens into the right side106and the rear side110of the main housing102. The recess142does not communicate with an interior of the main housing102(i.e. the volume defined between the front and rear housing portions116,118). It is contemplated that in another alternative embodiment the recess142could be defined in the rear housing portion118at the rear, left corner of the main housing102. It is also contemplated that in other alternative embodiments the recess142could additionally open in the top side112or the bottom side114. These embodiments include a recess142defined at the top, rear, left corner of the main housing102; at the top, rear, right corner of the main housing102; at the bottom, rear, left corner of the main housing102; or at the bottom, rear, right corner of the main housing102.

A pair of generally longitudinally extending keys152are provided on the bottom wall150of the recess142. Another pair of generally longitudinally extending keys154are provided on the top wall148of the recess142. The keys152,154are generally longitudinally extending bands protruding from the walls150,148. It is contemplated that more or less keys152,154could be provided. It is also contemplated that one or more keys could be provided on the left wall146. Other types of keys152,154are contemplated, such as dovetails for example.

As the ATV10illustrated inFIG.1is provided with a winch40, a winch switch156is provided. The winch switch156is mounted to a switch housing158. The switch housing158is received in the recess142as can be seen inFIGS.2to4and as will be described in more detail below. It is contemplated that in alternative embodiments, a switch used to control another optional equipment or accessory of the ATV10could be mounted to the switch housing158in addition to or instead of the winch switch156. For example, should the ATV10be equipped with heated hand grips32, the switch provided on the switch housing158could be a hand grip heating ON/OFF switch used to turn the heating of the hand grips32ON and OFF. Other examples of an optional equipment or accessory of the ATV that could be controlled by a switch mounted to the switch housing158include, but are not limited to, fog lights and an adjustable windshield. It is contemplated that in embodiments where additional switches are provided on the switch housing158, the switch housing158could be wider than illustrated in order to accommodate the additional switches. In such embodiments, the wider switch housing158, when installed in the recess142, would extend laterally outward of the right side106of the main housing102.

The winch switch156is connected to an electric wire160that extends inside the switch housing158, as shown in dotted lines inFIGS.3and4, and exits the switch housing158through a grommet161provided on the right side of the switch housing158. The electric wire160is connected to the winch motor of the winch40to control the operation of the winch40.

The winch switch156is a button having a reel-out position, a neutral position and a reel-in position. When the winch switch156is in the reel-out position, the winch cable42is reeled out from its initial position. When the winch switch156is in the neutral position, the winch cable42is not being actively being reeled-in or reeled-out. When the winch switch156is in the reel-in position, the winch motor reels-in the winch cable42.

With reference toFIGS.5to7, the switch housing158has a pair of generally longitudinally extending keyways162provided near a bottom thereof. Another pair of generally longitudinally extending keyways164are provided at the top of the switch housing158. The keyways162,164are generally longitudinally extending slots configured to receive the keys152,154respectively. It is contemplated that the keyways162,164could be generally longitudinally extending channels. It is contemplated that in embodiments where more or less keys152,154are provided, the switch housing158would have a corresponding number of keyways162,164. It is also contemplated that in embodiments where one or more keys are provided on the left wall146, the switch housing158would have a corresponding number of keyways provide on its left side. It is contemplated that in embodiments where keys152,154of a type other than the one illustrated, the housing158would be provided with keyways162,164configured to receive these keys152,154. It is also contemplated that the main housing102could define keyways in one or more walls of the recess142and that the switch housing158could be provided with one or more keys configured to be received in these keyways. It is also contemplated that in some embodiments, the keys152,154and the keyways162,164could be omitted.

As shown by arrow166inFIG.6, the switch housing158is inserted into the recess by sliding generally longitudinally into the recess142from the rear side110by engaging the keys152,154into the keyways162,164. Once the switch housing158is inserted in the recess142, the switch housing158is fastened to the rear housing portion118by a threaded fastener168. The fastener168is inserted through an aperture170defined on a right side of the switch housing158and a corresponding threaded aperture172defined in the rear housing portion118(seeFIG.7). It is contemplated that the switch housing158could be connected to the main housing102in other ways. For example, the switch housing158could be clipped to the main housing102. In another example, one of the walls of the recess142or the switch housing158could have a ferromagnetic metal plate mounted thereto, and the other of the one wall of the recess142and the switch housing158could be provided with a permanent magnet such that the switch housing158is magnetically connected to the main housing102.

When the switch housing158is connected to the main housing102, the winch switch156faces generally rearward. The electric wire160does not extend in the interior of the main housing102. As can be seen inFIGS.2to4, the shape of the switch housing158is complementary to the shape of the main housing102such that the switch housing158covers the openings defined in the right and rear sides106,110of the main housing102. In the present embodiment, the combination of the main housing102and the switch housing158give a visual appearance of a single housing even though two housings102,158are used.

When the ATV10is not provided with the winch40, which is an optional accessory of the ATV10, the winch switch156is not needed. Instead of having to provide a completely different switch assembly that does not have the winch switch156as in the prior art, the switch housing158and the winch switch156are replaced by a cap174that covers the recess142, as can be seen inFIG.8. Similarly, when the ATV10is not initially provided with the winch40, but the winch40is installed later, the cap174is removed and replaced with the switch housing158and the winch switch156.

In the present embodiment, as can be seen inFIGS.8and9, the cap174has essentially the same shape as the switch housing158, except that the cap174does not have the apertures for the winch switch156and the grommet161that the switch housing158defines. Like the switch housing158, the cap174has a pair of generally longitudinally extending keyways176provided near a bottom thereof and another pair of generally longitudinally extending keyways178provided at the top thereof. The keyways176,178are generally longitudinally extending slots configured to receive the keys152,154respectively. It is contemplated that the keyways176,178could be generally longitudinally extending channels.

Like the switch housing158, the cap174is inserted into the recess by sliding generally longitudinally into the recess142from the rear side110by engaging the keys152,154into the keyways176,178. Once the cap174is inserted in the recess142, the cap174is fastened to the rear housing portion118by the threaded fastener168. The fastener168is inserted through an aperture defined on a right side of the cap174(not shown, but like the aperture170of the switch housing158) and the threaded aperture172defined in the rear housing portion118.

As can be seen inFIG.8, the shape of the cap174is complementary to the shape of the main housing102such that the cap174covers the openings defined in the right and rear sides106,110of the main housing102. In the present embodiment, the cap174hides the recess142.

FIG.10illustrates a switch assembly200which is an alternative embodiment of the switch assembly100. For simplicity, elements of the switch assembly200that correspond to those of the switch assembly100have been labeled with the same reference numerals and will not be described again.

In the switch assembly200, the generally longitudinally extending keys152,154have been replaced by generally laterally extending keys (only the lower pair of keys202being shown). Accordingly, the generally longitudinally extending keyways162,164of the switch housing158have been replaced by generally laterally extending keyways (only the upper keyways204being shown). In this embodiment, the keyways of the switch housing158are channels, but it is contemplated that they could be slots. Similarly, with reference toFIG.11, the generally longitudinally extending keyways176,178of the cap174have been replace by generally laterally extending keyways206,208. The selected one of the switch housing158and the cap174is inserted into the recess142by sliding it generally laterally into the recess142from the right side106of the main housing102, such that the keys are received in the keyways.

FIGS.12and13illustrate a switch assembly300which is an alternative embodiment of the switch assembly100. For simplicity, elements of the switch assembly300that correspond to those of the switch assembly100have been labeled with the same reference numerals and will not be described again.

In the switch assembly300, the switch housing158has been replaced by a switch housing302to be received in the recess142. A pair of winch switches156A,156B are mounted on a rear side of the switch housing302. The winch switches156A,156B are used to control the winch40. When the winch switch156A is pressed, the winch motor reels-in the winch cable42. When the winch switch156B is in pressed, the winch cable42is reeled out from its initial position. It is contemplated that the switches156A,156B could be used to control one or more other vehicle components.

In the switch assembly300, the generally longitudinally extending keys154have been replaced by generally longitudinally extending keys304provided on the left wall146of the recess142. Accordingly, the generally longitudinally extending keyways164of the switch housing158have been replaced in the switch housing302by generally longitudinally extending keyways306(FIG.13) on a left side of the switch housing302. Similarly, a cap (not shown) to be used to cover the recess142when the switch housing302is not provided in the recess142would be similar to the cap174described above, but with the generally longitudinally extending keyways178of the cap174replaced by generally longitudinally extending keyways on a left side of the cap. The selected one of the switch housing358and the cap is inserted into the recess142by sliding it generally longitudinally into the recess142from the rear side110of the main housing102, such that the keys are received in the keyways.

In this embodiment, the electric wire160is inserted in a right side of the main housing102. More specifically, one end of the electric wire160is disposed inside the main housing102and connects to an electrical connector in the form of pins308. As can be seen inFIG.12, the pins308extends rearward from the front wall144of the recess. The electric wire160exits the main housing102via a grommet (not shown) provided on the rear housing portion118, on the lower right side106of the main housing102, and the portion of the electric wire160exiting the main housing102is fastened to a tab310by a tie-wrap312. In this embodiment, the electric cable138exits the main housing102via a grommet (not shown) provided on the front housing portion116, next to the electric wire160. As such, the tab139is also provided on the front housing portion116. By exiting the main housing102next to each other, the electric wire160and the electric cable138can easily be received in a common harness314. It is also contemplated that the electric wire160could enter the main housing102with the electric cable138. In such an embodiment, the tab310and the tie wrap312would be omitted.

An electrical connector in the form of pair of electrical conductive sleeves316is connected to the switch housing302. As can be seen inFIG.13, the sleeves316are inserted in the front wall of the switch housing302. The sleeves316are electrically connected to the switches156A,156B. By sliding the switch housing302into the recess142such that the keys152,304of the main housing102are received in the keyways162,306of the switch housing302respectively, the pins308are received in the sleeves316, thereby establishing an electrical connection. As a result, the switches156A,156B communicate with the winch motor of the winch40. It is contemplated that the pins308could be provided on the switch housing302and the sleeves316could be provided on the main housing102. It is also contemplated that other types of electrical connectors could be provided which would establish an electrical connection when the switch housing302is inserted in the recess142. When the cap is provided on the main housing102instead of the switch housing302, the cap covers the pins308, thereby protecting the pins308from damage.

It is contemplated that a switch assembly similar to the switch assembly100,200, or300could be mounted to the right side of the handlebar30instead of the switch assembly36.

Modifications and improvements to the above-described embodiments of the present invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present invention is therefore intended to be limited solely by the appended claims.