Floor type pedal assembly

Abstract

Embodiments in the present application relate to a pedal assembly for a vehicle. The pedal assembly includes a housing, a link member, a pedal arm, and a lever arm. The housing has a friction generating member extending from an inner surface of the sidewall. A pedal arm is coupled with a first end of the link member. The lever arm has a second lever end including a hub portion. The first lever end includes an attachment portion extending from the outer surface. The attachment portion is coupled with the second end of the link member. The hub portion abuts a friction generating member of the housing and moves when pressure is applied to the attachment portion. When the pedal arm is depressed, the lever arm moves the hub portion relative to the friction generating member of the housing with a load applied to the pedal arm to generate hysteresis.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 352,318, filed on June 15, 2022, entitled "Floor-Mounted Electronic Throttle Control Pedal Assembly," the entire contents of which are incorporated herein by reference. Technical Field

[0002] The present application relates generally to pedal assemblies for vehicles and, more particularly, to pedal assemblies that produce hysteresis during pedal movement. Background Art

[0003] Floor mounted accelerator pedal assemblies are well known. In the pedal assembly, an accelerator pedal is coupled or communicated with a throttle, replacing a mechanical linkage. Generally, an accelerator pedal assembly includes an accelerator pedal module, a throttle valve that can be opened and closed by an electric motor, and a powertrain or engine control module that uses software and calculations from data measured by other sensors to determine the desired throttle position. However, these known accelerator pedal assemblies are not configured to provide a position sensor output to a powertrain controller and a mechanical resistance with hysteresis to the driver's foot, both of which are related to the position of the pedal. Summary of the invention

[0004] In one embodiment, a pedal assembly is provided. The pedal assembly includes a housing, a connecting rod member, a pedal arm and a lever arm. The housing has a friction generating member extending from the inner surface of a side wall. The connecting rod member has a first end and an opposite second end. The pedal arm is connected to the first end of the connecting rod member. The lever arm has a first lever end and an opposite second lever end. The second lever end includes a hub portion. The first lever end includes an attachment portion extending from the outer surface of the first lever end. The attachment portion is connected to the second end of the connecting rod member. The hub portion abuts against the friction generating member of the housing and moves when pressure is applied to the attachment portion. When the pedal arm is pressed down, the lever arm uses the load applied to the pedal arm to move the hub portion relative to the friction generating member of the housing to generate hysteresis.

[0005] In another embodiment, a floor-type pedal assembly for a vehicle is provided. The floor-type pedal assembly includes a housing, a connecting rod member, a pedal arm, a lever arm, and a spring frame assembly. The housing has a friction generating member integrated with an inner surface of a side wall and extending from the inner surface of the side wall. The friction generating member is arc-shaped. The connecting rod member has a first end and an opposite second end. The pedal arm is coupled to the first end of the connecting rod member. The lever arm has a first lever end and an opposite second lever end. The second lever end includes a hub portion. The first lever end includes an attachment portion extending from an outer surface of the first lever end so that the attachment portion is coupled to the second end of the connecting rod member. The hub portion abuts against the friction generating member of the housing and moves when pressure is applied to the attachment portion. The spring frame assembly is located in the housing and includes: a spring frame having a spring receiving portion; and at least one spring extending between the lever arm and the spring frame. When the pedal arm is depressed, the lever arm moves the hub portion relative to the friction generating member of the housing to generate hysteresis by a load applied to the pedal arm.

[0006] In another embodiment, a pedal assembly is provided. The pedal assembly includes a housing, a connecting rod member, a pedal arm and a lever arm. The housing has a friction generating member extending from the inner surface of the side wall. The friction generating member is arc-shaped. The connecting rod member has a first end and an opposite second end. The pedal arm is connected to the first end of the connecting rod member. The lever arm has a first lever end and an opposite second lever end. The first lever end is connected to the second end of the connecting rod member. The second lever end of the lever arm includes a hub portion. The hub portion includes a first surface and a second surface. The second surface extends from a portion of the first surface. The second surface is semicircular to correspond to the arc of the friction generating member. The second surface abuts against the friction generating member of the housing and moves when pressure is applied to the connecting rod member. When the pedal arm is pressed down, the lever arm uses the load applied to the pedal arm to move the second surface of the hub portion relative to the friction generating member of the housing to generate hysteresis.

[0007] These and other features provided by the embodiments described herein will be more fully understood in view of the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The embodiments illustrated in the drawings are illustrative and exemplary in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments may be understood when read in conjunction with the following drawings, in which similar structures are indicated by similar reference numerals, and in which:

[0009] Figure 1 schematically depicts a front and right side perspective view of a pedal assembly in a starting position according to one or more embodiments shown and described herein;

[0010] Figure 2 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 A rear and right side perspective view of a pedal assembly;

[0011] Figure 3 Schematically depicts a fully depressed position according to one or more embodiments shown and described herein. Figure 1 A front and right side perspective view of a pedal assembly;

[0012] Figure 4 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 3 A rear and right side perspective view of a pedal assembly;

[0013] Figure 5 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 An exploded view of the pedal assembly;

[0014] Figure 6 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 a right side view of the pedal assembly with the connector assembly housing and pedal arm removed;

[0015] Figure 7 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 6 a right side view of the pedal assembly with the lever arm and a pair of springs further removed;

[0016] Figure 8 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 6 a right side view of the pedal assembly showing the side wall of the housing and the friction generating member;

[0017] Fig. 9A Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 An isolated perspective bottom view of a lever arm of a pedal assembly;

[0018] Fig. 9B Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 1 Isolated perspective side and bottom views of a linkage member of a pedal assembly; and

[0019] Fig.10 Schematically depicts a schematic diagram of a device according to one or more embodiments shown and described herein. Figure 3 Right side view of the pedal assembly with the connector assembly housing removed. DETAILED DESCRIPTION

[0020] Embodiments described herein relate to a floor-standing, accordion-type pedal assembly, such as an accelerator pedal assembly, configured to generate its own hysteresis within a housing using a hub portion of a lever arm that moves relative to a corresponding semicircular friction-generating member extending from an inner surface of a housing sidewall to generate hysteresis based on the amount of pivoting of a pedal pad.

[0021] The sensor assembly is mounted on the housing using a connector that extends from the housing and is configured to communicatively couple the sensor assembly to an electronic control unit, a powertrain control unit, or the like. The coupler is mounted in the wheel hub portion and is configured to rotate when the wheel hub rotates. Thus, the sensor assembly can track or determine movement of the coupler via a transmitting coil and at least one receiving coil located on or within a circuit board (such as a printed circuit board). Thus, the sensor assembly will sense the amount of force on the pedal pad at any given time based on the position of the coupler.

[0022] Various embodiments of pedal assemblies are described herein in detail.

[0023] As used herein, the term "communication connection" means that the connection components are able to exchange data signals with each other, for example, exchanging electrical signals via a network (such as via Wi-Fi, Bluetooth, etc.) via a conductive medium or a non-conductive medium, exchanging electromagnetic signals via the air, exchanging optical signals via optical waveguides, etc.

[0024] First refer to Figure 1-10 , Figure 1-10 The pedal assembly 10 is schematically depicted. The pedal assembly 10 includes a housing 12 and a pedal arm assembly 14. The pedal arm assembly 14 includes a pedal arm 16, a link member 52, a spring bracket assembly 58, and a lever arm 66. The pedal arm 16 includes a pedal pad end 18a and a pivot end 18b. In addition, the pedal arm 16 also includes an outer surface 20a and an opposing inner surface 20b spaced apart from the outer surface 20a to define a thickness of the pedal arm 16. In some embodiments, the pedal arm 16 is generally planar in shape. In other embodiments, the pedal arm 16 can be a different shape, such as a curved shape, an arc shape, etc. The pivot end 18b is pivotally coupled to the housing 12 about a pivot axis P1 to move or pivot about the pivot axis P1, such as Figure 1 For example, in the depicted embodiment, the pivot end 18 b is slidably engaged with the receiving slot 22 of the housing 12 .

[0025] In some embodiments, the pivot end 18b can be a plate 24 that is coupled to the distal end 26 of the pedal arm 16 via fasteners (such as screws, rivets, bolts, and nuts), press fits, epoxy resins, adhesives, welding, etc. Thus, the pivot end 18b can act as a living hinge to allow the pedal arm 16 to rotate about the pivot axis P1 in the direction indicated by arrow A1 between the starting position (such as Figure 1-2 ) and the fully depressed position (as shown Figure 3-4 as shown) and move between multiple depressed positions therebetween.

[0026] In some embodiments, the pivot end 18b may be generally T-shaped as shown, and the receiving slot 22 may have a corresponding shape to receive the pivot end 18b and allow the pivot end 18b to move or pivot around the pivot axis P1 within the receiving slot 22, as shown in FIG. Fig.10 This is not restrictive, and the pivot end 18b may be any shape, such as rectangular, square, hexagonal, octagonal, cylindrical, etc. In addition, the receiving slot 22 of the housing 12 may be any shape corresponding to the shape of the pivot end 18b to allow the pivot end 18b to pivot or move around the pivot axis P1, such as Figure 1 In addition, in other embodiments, the pivot end 18b can be connected to the housing 12 via fasteners such as screws, rivets, pins, dowels, bolts and nuts. In addition, in other embodiments, the distal end 26 can be directly connected to the housing 12 via fasteners such as screws, rivets, pins, dowels, bolts and nuts to act as a pivot end, so that the plate 24 is not required.

[0027] The outer surface 20a of the pedal arm 16 can be a pedal pad, or can receive a pedal pad on which a user's foot is pressed to brake, accelerate, and / or activate a clutch control. The inner surface 20b includes an attachment portion 48 and a leaf spring 100 extending from the attachment portion 48. The attachment portion 48 can include a pair of spaced-apart flanges 50a, 50b, which can include indentations and / or other mechanical devices and / or features to couple or attach the pedal arm 16 to the linkage member 52, as discussed in more detail herein. The leaf spring 100 can be configured to contact or otherwise engage a portion of the housing 12 when the pedal arm is approaching and / or in a fully depressed position, as discussed in more detail herein.

[0028] The housing 12 includes an upper wall 28a, an opposing lower wall 28b, a side wall 28c extending between the upper arm 28a and the lower wall 28b, and an end wall 28d. The upper wall 28a, the lower wall 28b, and the side wall 28c have outer surfaces 30a, 30b, 30c, 30d, respectively, and opposing inner surfaces 32a, 32b, 32c, 32d, which define a cavity 34 between the respective inner surfaces 32a, 32b, 32c, 32d. The connector assembly housing 36 forms opposing side walls to enclose the cavity 34 when installed, as discussed in more detail herein. The friction generating member 38 extends from the inner surface 32c of the side wall 28c. In some embodiments, the friction generating member 38 is integrally formed with the inner surface 32c of the side wall 28c as a unitary structure with the side wall 28c. In other embodiments, the friction creating member 38 may be coupled to the inner surface 32c of the sidewall 28c via fasteners (such as, but not limited to, screws, rivets, bolts, and nuts), adhesives, epoxies, welds, and the like.

[0029] In some embodiments, the friction generating member 38 may include an inner surface 40a and an opposite outer surface 40b. In some embodiments, the inner surface 40a may have a smooth profile. In other embodiments, the inner surface 40a may include a pad or other material to form a smooth profile. The friction generating member 38 and / or its inner surface 40a may be arc-shaped. For example, the friction generating member 38 and / or its inner surface 40a may be semicircular, semi-circular, etc. In other embodiments, the friction generating member 38 and / or its inner surface 40a may be other shapes, such as circular, hexagonal, octagonal, etc. Therefore, in other embodiments, the friction generating member 38 and / or its inner surface 40a may not be arc-shaped, or may include an arc-shaped portion. In addition, the friction generating member 38 may extend from the inner surface 32a and / or the inner surface 32c, and may define a portion of the cavity 34.

[0030] In addition, guide member 49 extends from inner surface 32c of side wall 28c. In some embodiments, guide member 49 is integrally formed with inner surface 32c of side wall 28c as a unitary structure with side wall 28c. In other embodiments, guide member 49 may be coupled to inner surface 32c of side wall 28c via fasteners (such as, but not limited to, screws, rivets, bolts, and nuts), adhesives, epoxies, welding, etc.

[0031] In some embodiments, guide member 49 may include inner surface 51a and opposite outer surface 51b. In some embodiments, outer surface 51b may have a smooth profile. In other embodiments, outer surface 51b (varied from 50A / 50B) may include a pad or other material to form a smooth profile. Guide member 49 may be circular. In other embodiments, guide member 49 may be other shapes, such as square, rectangular, hexagonal, octagonal, etc.

[0032] Still refer to Figure 1-10 , the upper wall 28a also includes an opening 42 and a receiving channel 44, and the receiving channel 44 is located within the outer surface 30a to receive a shock absorber 46 or a buffer block. The shock absorber 46 or the buffer block can be an elastic material, rubber, etc., and is configured to cushion the pedal arm 16 and provide an end of travel of the pedal arm 16 when in the fully depressed position. In addition, the shock absorber 46 or the buffer block can be slidably engaged in the receiving channel 44 to lock or retain the shock absorber 46 or the block in the receiving channel 44. The opening 42 provides an entrance to the cavity 34 of the housing 12. In addition, in some embodiments, the inner surface 32a of the upper wall 28a may include a receiving channel 104 for receiving a shock absorber 106 or a buffer block. The shock absorber 106 or the buffer block can be an elastic material, rubber, etc., and is configured to cushion the lever arm 66 when the pedal arm 16 is in the starting position, such as Figure 6 In other words, the shock absorber 106 can be configured to engage or abut against a surface of the lever arm 66 when the pedal arm is in the starting position to reduce noise, vibration, and / or harshness. In addition, the shock absorber 106 or the buffer block can be slidably engaged in the receiving channel 104 to lock or retain the shock absorber 106 or the block in the receiving channel 104.

[0033] The cavity 34 can be defined by a floor surface 54a, a terminating cavity wall surface 54b, and a friction generating member 38, such that the friction generating member 38 extends between and from the floor surface 54a and / or the inner surface 32b of the upper wall 28a at one end of the cavity 34, while the terminating cavity wall surface 54b is located at the opposite end, and the floor surface 54a is between the friction generating member 38 and the terminating cavity wall surface 54b. The protrusion 56 extends from the floor surface 54a. In some embodiments, the protrusion 56 can be formed as a unitary structure with the floor surface 54a. In other embodiments, the protrusion 56 can be coupled or otherwise attached to the floor surface 54a via fasteners (such as bolts and nuts, screws, rivets), adhesives, epoxies, welding, etc. The protrusion 56 can be configured to fix the spring bracket assembly 58 in a suitable position within the cavity 34, as discussed in more detail herein.

[0034] In some embodiments, the shock absorber 102 can extend from the outer surface 30a of the upper wall 28a. The shock absorber 102 can be configured to engage or otherwise contact the leaf spring 100 of the pedal arm 16 when the pedal arm is in or near the fully depressed position, such as Figure 4 Thus, the interaction of the shock absorber 102 and the leaf spring 100 can provide the user with an ideal feel when the pedal arm 16 is pushed into the fully depressed position.

[0035] In some embodiments, the housing 12 may be a molded plastic. For example, the housing 12 may be formed of various materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / polyoxymethylene), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as ultraviolet absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. may be added.

[0036] In other embodiments, the shell 12 can be additively manufactured. Additive manufacturing generally refers to a manufacturing process in which successive layers of material are superimposed on each other to "build up" a three-dimensional component "layer by layer." Successive layers are typically fused together to form a monolithic component that may have various integral subcomponents. Although additive manufacturing techniques are described herein as enabling the manufacture of complex objects by building objects point by point and layer by layer (usually in a vertical direction), other manufacturing methods are also possible and are within the scope of the present subject matter. For example, although the present invention discusses adding materials to form successive layers, it will be understood by those skilled in the art that the methods and structures disclosed herein may be implemented by any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use a layer addition process, a layer subtraction process, or a hybrid process.

[0037] Suitable additive manufacturing techniques according to the present disclosure include, for example, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing (such as inkjet and laser printing), stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shaping (LENS), laser net shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM) and other known processes.

[0038] The housing 12 may be floor-standing. In other words, in some embodiments, the housing 12 may be coupled or mounted within or extend from a floor surface of the vehicle. Thus, the cavity 34 of the housing accommodates the pedal arm 16 when fully depressed to allow the pedal arm 16 to be in a starting position (e.g., Figure 1-2 ) and the fully depressed position (as shown Figure 3-4 as shown).

[0039] Still refer to Figure 1-10 , the link member 52 includes a proximal end 60a and an opposite distal end 60b, and an elongated member 59 between the proximal end 60a and the distal end 60b. The elongated member 59 may be arcuate or curved. This is not restrictive, and the elongated member 59 may be linear. The proximal end 60a includes a pedal attachment portion 62a, and the distal end 60b includes a lever arm attachment portion 62b. The pedal attachment portion 62a may include a plurality of spaced flanges 64 extending from the proximal end 60a. Each of the plurality of spaced flanges 64 corresponds to a pair of spaced flanges 50a, 50b of the attachment portion 48, so that the plurality of spaced flanges 64 are connected to a pair of spaced flanges 50a, 50b. In some embodiments, the connection of the plurality of spaced flanges 64 to a pair of spaced flanges 50a, 50b may adopt a snap-fit ​​configuration. In other embodiments, a plurality of spaced apart flanges 64 are coupled to a pair of spaced apart flanges 50a, 50b via fasteners (such as screws, rivets, pins, bolts, and nuts), adhesives, epoxies, welding, or the like.

[0040] The lever arm attachment portion 62b includes a receiving cavity 77 and a coupling portion 79. The coupling portion 79 may include a tubular portion 89 or shape that is received by the lever arm 66, as discussed in greater detail herein.

[0041] In some embodiments, the connecting rod member 52 can be a molded plastic. For example, the connecting rod member 52 can be formed by various materials, such as acrylonitrile-butadiene-styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile-butadiene-styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / polyoxymethylene), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as ultraviolet absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. can also be added. In other embodiments, the connecting rod member 52 can be manufactured by additive manufacturing. In other embodiments, the connecting rod member 52 can be formed by metal materials (such as steel, iron, copper, aluminum, alloys, and combinations thereof, etc.).

[0042] Still refer to Figure 1-10, the lever arm 66 includes a first end 68a and an opposite second end 68b. The second end 68b includes a hub portion 70. The first end 68a includes an inner surface 72a and an opposite outer surface 72b. The attachment portion 74 extends from the outer surface 72b of the first end 68a so that the attachment portion 74 is coupled to the lever arm attachment portion 62b of the distal end 60b of the link member 52. The attachment portion 74 includes a pair of spaced flanges 76, each of which includes a hole 75a, 75b, and the holes 75a, 75b are configured to receive a coupling portion 79 to couple the attachment portion 74 of the lever arm 66 to the lever arm attachment portion 62b of the link member 52. In other embodiments, the attachment portion 74 of the lever arm 66 is coupled to the lever arm attachment portion 62b of the link member 52 via fasteners (such as screws, rivets, pins, bolts and nuts), adhesives, epoxy resins, welding, etc.

[0043] The spring receiving groove 87 is located at and extends within the inner surface 72a of the first end 68a of the lever arm 66. The spring receiving groove 87 is used to receive at least one spring. In the illustrated embodiment, the at least one spring is a pair of springs, wherein the at least one spring is depicted as an outer spring 78, an inner spring 80 located within the inner diameter ID1 of the outer spring 78, and a damper 85, the outer diameter OD1 of the damper 85 being smaller than the inner diameter ID1 of the outer spring 78, so that the damper 85 can be located within the inner diameter ID1 of the outer spring 78. The inner diameter ID2 of the damper 85 can be larger than the outer diameter OD2 of the inner spring 80, so that the inner spring 80 is received within the inner diameter ID2 of the damper 85. Therefore, the spring receiving groove 87 receives the first terminal end 79a of the outer spring 78 and the first terminal end 81a of the inner spring 80, as discussed in more detail herein.

[0044] The hub portion 70 includes a first surface 82a and a second surface 82b, the first surface 82a being generally circular and including an end wall 82c and an opposing receiving cavity 82d, the receiving cavity 82d being configured to receive the guide member 49 of the side wall 28c. Thus, the shape and size of the receiving cavity 82d are generally designed to receive the guide member 49. The first surface 82a has a diameter D1. The second surface 82b extends from a portion of the first surface 82a to partially overlap, abut and / or cover a portion of the first surface 82a. For the portion of the first surface 82a that the second surface 82b partially overlaps, abuts and / or covers, the second surface 82b follows the contour or geometry of the first surface 82a. Thus, the second surface 82b extends from the first surface 82a as a single integral structure with the first surface 82a. The second surface 82b is arcuate to match or correspond to the shape of the friction generating member 38. Thus, the second surface 82b may be arcuate, semicircular, semi-annular, etc. The second surface 82b has a second diameter D2 (eg, across the length of the hub portion, such as Fig. 9A), the second diameter D2 (e.g., length) is greater than the first diameter D1 (e.g., length) of the first surface 82a at least where the second surface extends from the first surface 82a (e.g., the diameter of the first surface 82a is smaller than the diameter of the second surface 82b).

[0045] The second surface 82b abuts the inner surface 40a of the friction generating member 38. When the second surface 82b moves relative to the inner surface 40a of the friction generating member 38, such as by rotation, hysteresis is generated, as discussed in more detail herein. In addition, the guide member 49 guides the hub portion 70 during movement of the hub portion 70 (e.g., the second surface 82b relative to the inner surface 40a of the friction generating member 38). Therefore, in operation, when a load is applied to the pedal arm 16 (e.g., Figure 3 , Figure 4 and Fig.10 ), the link member 52 applies a load to the first end 68a of the lever arm 66, thereby moving the hub portion 70 so that the second surface 82b moves relative to the inner surface 40a of the friction generating member 38 to generate hysteresis, as discussed in more detail herein.

[0046] In some embodiments, the lever arm 66 can be a molded plastic. For example, the lever arm 66 can be formed of various materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / polyoxymethylene), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as ultraviolet absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. can also be added. In other embodiments, the lever arm 66 can be additively manufactured. In other embodiments, the lever arm 66 can be formed of a metal material (such as steel, iron, copper, aluminum, alloys, and combinations thereof, etc.).

[0047] Still refer to Figure 1-10, the spring holder assembly 58 includes an outer spring 78, an inner spring, a spring holder 84, and a damper 85. The spring holder 84 includes a recessed portion 86 and a spring retaining portion 88 located on an upper surface 90a and a groove 92 located on a lower surface 90b. The groove 92 can slidably receive the protrusion 56 extending from the floor surface 54a to lock or retain the spring holder 84 to the floor surface 54a of the cavity 34 of the housing 12. The radius of the recessed portion 86 matches the radius of the first surface 82a of the hub portion 70, so that the recessed portion 86 is configured to receive the first surface 82a. Therefore, the first surface 82a abuts the upper surface 90a at the recessed portion 86 of the spring holder 84. It should be understood that the second surface 82b abuts the inner surface 40a of the friction generating member 38 and the first surface 82a (e.g., the portion of the first surface 82a where the second surface 82b does not extend from the first surface 82a). Therefore, when a load is applied to the pedal arm 16, the lever arm 66 utilizes the load applied to the pedal arm 16 to move the first surface 82a of the hub portion 70 relative to the recessed portion 86 of the spring bracket 84 and / or to move it within the recessed portion 86 of the spring bracket 84. As a result, the hub portion 70 rotates within the recessed portion 86 of the spring bracket 84.

[0048] The spring retaining portion 88 includes a groove 94 configured to receive the second terminal end 81b of the inner spring 80 and the second terminal end 79b of the outer spring 78. Therefore, the outer spring 78, the inner spring 80 and the shock absorber 85 extend linearly in the direction between the lever arm 66 and the spring frame 84, and the outer spring 78 and the inner spring 80 extend between the lever arm 66 and the spring frame 84 and contact the lever arm 66 and the spring frame 84. Each of the outer spring 78 and the inner spring 80 can be compressed between the groove 94 of the spring retaining portion 88 of the spring frame 84 and the spring receiving groove 87 of the lever arm 66. In some embodiments, the outer spring 78 and the inner spring 80 can each be made of stainless steel, wire, carbon steel, alloy steel, Elgiloy non-magnetic alloy, monel, etc. The outer spring 78 and the inner spring 80 may be formed of a composite material. In addition, the outer spring 78 and the inner spring 80 may be formed of different materials, or may be formed of the same material. In addition, each of the outer spring 78 and the inner spring 80 may be formed to have different potential energies.

[0049] In some embodiments, the spring frame 84 can be a molded plastic. For example, the spring frame 84 can be formed of various materials, such as acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile butadiene styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / polyoxymethylene), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as ultraviolet absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. can also be added. In other embodiments, the spring frame 84 can be additively manufactured. In other embodiments, the spring frame 84 can be formed of metal materials (such as steel, iron, copper, aluminum, alloys, and combinations thereof, etc.).

[0050] In addition, in some embodiments, the shock absorber 85 can be a molded plastic. For example, the shock absorber 85 can be formed of various materials, such as acrylonitrile-butadiene-styrene (ABS), polyethylene (PE), polypropylene (PP), polycarbonate (PC), nylon, polycarbonate / acrylonitrile-butadiene-styrene, polyurethane, polymethyl methacrylate, high-density polyethylene, low-density polyethylene, polystyrene, PEEK, POM (acetal / polyoxymethylene), polyethylene terephthalate, thermoplastic elastomer, polyetherimide, thermoplastic vulcanizate, polysulfone, combinations thereof, etc. In addition, additives such as ultraviolet absorbers, flame retardants, colorants, glass fibers, plasticizers, etc. can also be added. In other embodiments, the shock absorber 85 can be manufactured by additive manufacturing. In other embodiments, the shock absorber 85 can be formed of metal materials (such as steel, iron, copper, aluminum, alloys, and combinations thereof, etc.).

[0051] The connector assembly 107 is located on and extends from the connector assembly housing 36. The connector assembly 107 may include a connector 108, a plurality of terminals 110 located therein, and a circuit board 97 to communicatively couple the pedal assembly 10 with other components of the vehicle (such as an electronic control module and / or a powertrain controller). In some embodiments, portions of the connector assembly housing 36 and / or the connector assembly 107 and / or the sensor assembly 96 may be formed of an overmolded material. The circuit board 97 may be a printed circuit board, a flexible circuit board, etc.

[0052] The circuit board 97 may include at least one transmitter coil 98a and at least one receiver coil 98b. The sensor assembly 96 may also include a coupling 99 that may be mounted or attached to the end wall 82c of the hub portion 70 of the lever arm 66. Thus, the coupling 99 may be positioned adjacent to the at least one receiver coil 98b and / or the at least one transmitter coil 98a. In some embodiments, the coupling 99 may include different blades 112, such as Fig.10 . When a load applied to the pedal arm 16 moves the link member 52, which in turn moves the lever arm 66, thereby rotating the hub portion 70, the connector 99 can rotate or pivot when the hub portion 70 of the lever arm 66 moves. In some embodiments, the outermost portion of each blade 112 is located within the outer diameter of at least one transmitter coil 98a, and at least one receiver coil 98b is located within the outer diameter of at least one transmitter coil 98a. This is not limiting, and the outermost portion of each blade 112 can be located outside the outer diameter of at least one transmitter coil 98a, and / or a portion of at least one receiver coil 98b can be located outside the outer diameter of at least one transmitter coil 98a.

[0053] At least one receiver coil 98b and at least one transmitter coil 98a detect movement of the connector 99 and transmit data to an ECU and / or powertrain controller communicatively coupled to the sensor assembly 96 via connector 108. The sensor assembly 96 may include an overmold for encapsulating electronic components and may also include solderless connections between the PWA and terminal pins (such as compatible through-hole pins).

[0054] It should now be understood that the embodiments described herein relate to a pedal assembly that is configured to generate its own hysteresis within a housing using a hub portion of a lever arm that moves relative to a corresponding semicircular friction generating member extending from an inner surface of a side wall of the housing to generate hysteresis based on the amount of pivoting of the pedal arm.

[0055] It is noted that the terms "substantially" and "approximately" may be used herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

[0056] Although specific embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. In addition, although various aspects of the claimed subject matter have been described herein, these aspects need not be used in combination. Therefore, the appended claims cover all such changes and modifications within the scope of the claimed subject matter.

Claims

1. A pedal assembly, comprising: a housing having a friction generating member extending from an inner surface of the side wall; a link member having a first end and an opposing second end; a pedal arm coupled to the first end of the link member; as well as a lever arm having a first lever end and an opposing second lever end, the second lever end including a hub portion, the first lever end including an attachment portion extending from an outer surface of the first lever end, the attachment portion being coupled to the second end of the link member, the hub portion abutting the friction generating member of the housing and moving when pressure is applied to the attachment portion, When the pedal arm is depressed, the lever arm moves the hub portion relative to the friction generating member of the housing by a load applied to the pedal arm to generate hysteresis.

2. The pedal assembly according to claim 1, wherein: The friction generating member is integrated with the side wall as a single structure.

3. The pedal assembly according to claim 1, wherein: The friction generating member is arc-shaped.

4. The pedal assembly according to claim 3, wherein: The hub portion includes a first surface and a second surface, the second surface being semicircular to correspond to the arc shape of the friction generating member.

5. The pedal assembly according to claim 4, wherein: When the pedal arm is depressed, the lever arm moves the second surface of the hub portion relative to the friction generating member of the housing by the load applied to the pedal arm to generate the hysteresis.

6. The pedal assembly according to claim 4, wherein: The first surface of the hub portion is circular, and a diameter of the first surface is smaller than a diameter of the second surface.

7. The pedal assembly according to claim 4, wherein: The second surface extends from a portion of the first surface, and the first surface of the hub portion is rounded.

8. The pedal assembly according to claim 4, further comprising: A spring frame assembly is located in the housing, and the spring frame assembly includes: a spring holder having a spring receiving portion and a recessed portion; and At least one spring extends between the lever arm and the spring receiving portion, wherein the lever arm moves the first surface of the hub portion relative to the recessed portion by the load applied to the pedal arm when the pedal arm is depressed.

9. The pedal assembly according to claim 8, wherein: The lever arm further comprises: A spring receiving groove is located at the inner surface of the first lever end, and the spring receiving groove is configured to receive the other end of the at least one spring so that the at least one spring extends between the spring receiving groove of the lever arm and the spring receiving portion of the spring bracket.

10. The pedal assembly of claim 1, further comprising: A sensor assembly having: a coupling rotatably mounted to one side of the hub portion; at least one receiver coil positioned adjacent to the coupler; as well as at least one transmitter coil, Wherein movement of the coupling is detected by the at least one receiver coil.

11. The pedal assembly according to claim 1, wherein: The resulting hysteresis is proportional to the load applied to the pedal arm.

12. A floor-mounted pedal assembly for a vehicle, the floor-mounted pedal assembly comprising: a housing having a friction generating member integrated with and extending from an inner surface of a side wall, the friction generating member being arc-shaped; a link member having a first end and an opposing second end; a pedal arm coupled to the first end of the link member; a lever arm having a first lever end and an opposing second lever end, the second lever end including a hub portion, the first lever end including an attachment portion extending from an outer surface of the first lever end such that the attachment portion is coupled to the second end of the link member, the hub portion abutting the friction generating member of the housing and moving when pressure is applied to the attachment portion; as well as A spring frame assembly is located in the housing, and the spring frame assembly includes: a spring holder having a spring receiving portion; and at least one spring extending between the lever arm and the spring bracket, When the pedal arm is depressed, the lever arm moves the hub portion relative to the friction generating member of the housing by a load applied to the pedal arm to generate hysteresis.

13. The floor-standing step assembly according to claim 12, wherein: The lever arm further includes a spring receiving recess at an inner surface of the first lever end; The at least one spring further includes a pair of terminal ends, one of the pair of terminal ends being received in the spring receiving groove, and the other of the pair of terminal ends being received in the spring receiving groove of the lever arm.

14. The floor-standing pedal assembly according to claim 12, wherein: The hub portion includes a first surface and a second surface, the second surface being semicircular to correspond to the arc shape of the friction generating member.

15. The floor-standing pedal assembly according to claim 14, wherein: When the pedal arm is depressed, the lever arm moves the second surface of the hub portion relative to the friction generating member of the housing by the load applied to the pedal arm to generate the hysteresis.

16. The floor-standing pedal assembly according to claim 14, wherein: The first surface of the hub portion is circular, and a diameter of the first surface is smaller than a diameter of the second surface.

17. The floor-standing pedal assembly according to claim 14, wherein: The second surface of the hub portion extends from a portion of the first surface, and the first surface of the hub portion is rounded.

18. The floor-standing pedal assembly according to claim 14, wherein: The spring frame also includes: The concave part, When the pedal arm is depressed, the lever arm moves the first surface of the hub portion relative to the recessed portion using the load applied to the pedal arm.

19. The floor-standing pedal assembly according to claim 12, further comprising: A sensor assembly having: a coupling rotatably mounted to one side of the hub portion; at least one receiver coil positioned adjacent to the coupler; as well as at least one transmitter coil, Wherein movement of the coupling is detected by the at least one receiver coil.

20. A pedal assembly comprising: a housing having a friction generating member extending from an inner surface of the side wall, the friction generating member being arc-shaped; a link member having a first end and an opposing second end; a pedal arm coupled to the first end of the link member; as well as a lever arm having a first lever end and an opposing second lever end, the first lever end being coupled to the second end of the link member, the second lever end of the lever arm including a hub portion, the hub portion including a first surface and a second surface, the second surface extending from a portion of the first surface, the second surface being semicircular to correspond to the arc of the friction generating member, the second surface abutting against the friction generating member of the housing and moving when pressure is applied to the link member, When the pedal arm is depressed, the lever arm moves the second surface of the hub portion relative to the friction generating member of the housing to generate hysteresis by using a load applied to the pedal arm.

Images