Integrated brake pedal for passenger vehicle

Abstract

An integrated brake pedal for a vehicle such as but not limited to an aircraft may include a pedal housing with a first side, a second side, and a receiving area between the first side and the second side. A shaft extending through the receiving area of the pedal housing and defines an axis of rotation of the integrated brake pedal. The shaft may include a return device applying rotational force to the pedal housing. The integrated brake pedal may include a position sensor positioned within the receiving area of the pedal housing and configured to detect angular rotation of the shaft and / or a mechanical stop feature within the receiving area of the pedal housing and configured to limit rotation of the pedal housing.

Description

INTEGRATED BRAKE PEDAL FOR PASSENGER VEHICLEFIELD OF THE INVENTION

[0001] The field of the invention relates to passenger vehicles, and, more particularly, to brake pedals for passenger vehicles.BACKGROUND

[0002] V ehicles, such as aircraft, buses, trains, ships, and automobiles, often include one or more safety features. One such safety feature may include a brake system that may be used as a control to provide input to stop a vehicle or otherwise control at least a speed of the vehicle to prevent catastrophic events such as a crash that may cause property damage, injury, or even death.

[0003] Brake systems may be complicated mechanical assemblies and may include multiple features and / or components. As an example, existing solutions for brake controls for pilots of an aircraft generally include a brake pedal that rotates on a shaft to allow for brake inputs from the pilot through force application to the top of the pedal. In these traditional approaches, the angular rotation of the pedal is linked to external devices such as sensors, return devices, and mechanical stop features through a crank attached to the pedal. However, such approaches require a significant amount of space in the cockpit and require additional linkages to couple the external devices to the pedal. Additionally, the many elements of traditional brakes, particularly in the aircraft, may be difficult to maintain, repair, and / or replace due to the various connects to the external devices and the various re-adjustments that would be required upon re-installation or otherwise.SUMMARY

[0004] The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claimsbelow. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.

[0005] According to certain embodiments of the present invention, an integrated brake pedal for a vehicle includes a pedal housing with a first side, a second side opposite the first side, and a receiving area between the first side and the second side. The integrated brake pedal also may include a shaft extending through the receiving area of the pedal housing. The shaft defines an axis of rotation of the integrated brake pedal and may include a return device for applying rotational force to the pedal housing. A position sensor may be positioned within the receiving area of the pedal housing for detecting angular rotation of the shaft and / or the integrated brake pedal. A mechanical stop feature may be within the receiving area of the pedal housing for limiting rotation of the pedal housing.

[0006] In some embodiments, the pedal housing includes a side support at the first side, and the return device is coupled to the side support of the pedal housing at the first side and is coupled to the shaft proximate to the second side of the pedal housing.

[0007] In various embodiments, the return device is within the shaft. In various embodiments, the return device is a spring. In certain embodiments, the spring is a first spring, and the shaft further includes a second spring for applying rotational force to the pedal housing. The first spring and the second spring may be concentric with respect to one another. In some embodiments, the pedal housing includes a side support laterally offset from a central axis of the pedal housing. Optionally, a first end of the first spring is coupled to the shaft at a first point on the shaft laterally offset from a central axis of the pedal housing, a second end of the first spring is coupled to the side support, a first end of the second spring is coupled to the shaft at a second point on the shaft laterally offset from the central axis of the pedal housing, and a second end of the second spring is coupled to the side support.

[0008] In certain cases, the integrated brake pedal is rotatable between a braking position and a rest position, and the return device biases the pedal housing to the rest position. In various embodiments, the return device is within an enclosed portion of the receiving area.

[0009] In some embodiments, the pedal housing includes a front side and a back side, and the front side defines an engagement surface for receiving an input from a user and the receiving area is recessed in the back side of the pedal housing.

[0010] In various embodiments, the receiving area includes an enclosed portion and an open portion. In certain examples, the position sensor is within the open portion and the shaft is within the enclosed portion. In various aspects, the position sensor is coupled with the shaft via a geared insert extending through a slot defined in the pedal housing.

[0011] In certain embodiments, the mechanical stop feature is on the shaft.

[0012] In various examples, the position sensor is a first position sensor, and the spring as the return device is a first spring, and the integrated brake pedal includes a second position sensor and a second spring, with the second spring positioned concentric with respect to the first spring. In some cases, the integrated brake pedal includes a first gear coupled to the first position sensor, a second gear coupled to the second position sensor, a first geared insert coupled to the shaft and engaged with the first gear, and a second geared insert coupled to the shaft and engaged with the second gear. Optionally, a pre-load spring may be connected to the first gear and to the second gear, and the pre-load spring may be adjustable to apply preload on the pedal housing and in response to the pedal housing receiving a brake-applying force.

[0013] According to certain embodiments, a braking system for an aircraft includes the integrated brake pedal and a shaft coupling the integrated brake pedal to the aircraft.

[0014] According to certain embodiments of the present invention, an integrated brake pedal for a vehicle includes a pedal housing with a front side, a back side, and a receiving area defined in the back side of the pedal housing. The integrated brake pedal includes a brake control feature within the receiving area of the pedal housing, and the brake control feature includes at least one of a mechanical stop feature, a return device, or a position sensor.

[0015] In certain cases, the receiving area includes an open portion and an enclosed portion, the position sensor is within the open portion, and the return device is within the enclosed portion.

[0016] In various embodiments, the integrated brake pedal includes a shaft extending through the receiving area and defining an axis of rotation of the integrated brake pedal. Optionally, the return device is within the shaft and concentric with the shaft.

[0017] According to certain embodiments of the present invention, an integrated brake pedal for a vehicle includes a pedal housing with a front side, a back side, and a receiving area defined in the back side of the pedal housing. The receiving area may include an open portion and an enclosed portion. The integrated brake pedal further includes a shaft extending through the enclosed portion of the receiving area of the pedal housing, and the shaft defines an axis of rotation of the integrated brake pedal. A return device may be within the shaft and concentric with the shaft, and the return device may apply rotational force to the pedal housing.

[0018] In some embodiments, the integrated brake pedal additionally includes a mechanical stop feature and a position sensor within the receiving area.

[0019] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG. 1 A is a perspective view of an integrated brake pedal for a vehicle according to some embodiments of the present disclosure.

[0021] FIG. IB is a perspective view of the integrated brake pedal of FIG. 1A with internal components visible.

[0022] FIG. 2A is a sectional, perspective view of a forward portion of the integrated brake pedal of FIG. 1A.

[0023] FIG. 2B is a sectional, perspective view of a rear portion of the integrated brake pedal of FIG. 1A.

[0024] FIG. 3 is a sectional front view of the integrated brake pedal of FIG. 1 A.

[0025] FIG. 4A is a perspective view of a rear of the integrated brake pedal of FIG. 1 A.

[0026] FIG. 4B is a perspective view of a rotary variable differential transformer sensor of the integrated brake pedal of FIG. 1 A.

[0027] FIG. 5 is a sectional view of gears of the integrated brake pedal of FIG. 1A.

[0028] FIG. 6 is a perspective view of the gears of FIG. 5.

[0029] FIG. 7 is a component-level diagram of the integrated brake pedal of FIG. 1 A.

[0030] FIG. 8 is a sectional view of another shaft for an integrated brake pedal according to embodiments.

[0031] FIG. 9 is a partially exploded side view of an integrated brake pedal with the shaft of FIG. 8 according to embodiments.DETAILED DESCRIPTION

[0032] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

[0033] The described embodiments of the invention provide integrated brake pedals for vehicles. While the integrated brake pedals are discussed for use with respect to an aircraft, they are by no means so limited. Rather, embodiments of the integrated brake pedals may be used in vehicles of any type or otherwise as desired. Compared to traditional approaches, the brake pedals described herein provide a pedal with components for brake pedal control, such as but not limited to fly-by-wire brake pedal control, integrated in the pedal itself. As nonlimiting examples, components or features for brake pedal control such as position sensors, return devices, and mechanical stop features, among others, may be integrated in the pedal itself. As such, the integrated brake pedals described herein provide a single line replaceableunit, thereby allowing for improved installation, maintenance, and / or removal as needed compared to traditional approaches. The integrated brake pedals described herein may occupy a reduced amount of space compared to traditional approaches, thereby freeing up weight and / or space for other components as needed and without interfering with operation of the brake pedal with the foot of the pilot. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0034] FIGS. 1A-7 illustrate an integrated brake pedal 100 for a vehicle according to embodiments of the present disclosure. In the embodiments illustrated, the integrated brake pedal 100 is utilized on an aircraft, although in other embodiments, the integrated brake pedal 100 may be utilized on other vehicles as desired. As discussed in greater detail below, the integrated brake pedal 100 generally includes brake control features integrated within a pedal. In one non-limiting example, the integrated brake pedal 100 is utilized in an aircraft for flyby-wire brake pedal control. In some embodiments, the integrated brake pedal 100 may include an attachment feature 250, which may be used to couple the integrated brake pedal 100 to a shaft and thus to other components (e.g., rudder, brakes to landing gear wheels, etc.) of the aircraft or other vehicle in which the integrated brake pedal 100 is installed.

[0035] In various embodiments, the integrated brake pedal 100 includes a pedal housing 102 having a front side 103 and a back side 105 opposite from the front side 103. The integrated brake pedal 100 may further include a first side 208 and a second side 210. Optionally, the first side 208 and the second side 210 may be lateral sides of the brake pedal 100.

[0036] The front side 103 may be engaged by a user, such as, but not limited, to a pilot, during use of the integrated brake pedal 100. Engagement of the integrated brake pedal 100 by a user, such as but not limited to a location at or proximate to a free or top end 131 of the pedal housing 102, may cause the integrated brake pedal 100 to pivot or rotate about an axis 106. Optionally, the front side 103 includes surface features 107 such as but not limited to ribs to facilitate engagement between the user and the brake pedal 100.

[0037] The back side 105 of the pedal housing 102 defines a receiving area 109. As discussed in detail below, various brake control features may be housed, positioned, or otherwise retained within the receiving area 109. In various embodiments, the receiving area109 is recessed into the back side 105. In certain embodiments, and as best illustrated in FIG. 2B, the receiving area 109 includes an open portion 111 and an enclosed portion 206.

[0038] In various embodiments, brake control features may be within the open portion 111 and / or the enclosed portion 206. In certain embodiments, the enclosed portion 206 may be an opening or aperture that extends through the pedal housing 102 from the first side 208 to the second side 210.

[0039] While components within the open portion 111 may be exposed on the back side 105, the enclosed portion 206 of the receiving area 109 includes a wall 113 covering and / or at least partially enclosing the components contained therein. Optionally, components within the enclosed portion 206 may be accessed through the first side 208 and / or the second side 210. In certain embodiments, the pedal housing 102 includes a side support 115 at the first lateral side 208 or the second lateral side 210 and at least partially defining the enclosed portion 206. Optionally, side supports 115 may be provided on both lateral sides 208, 210. Optionally, and as best illustrated in FIGS. 4A, 5, and 6, the wall 113 includes one or more slots 117, and as discussed in detail below, one or more brake control features or sub-components may extend through the slots 117.

[0040] Optionally, the pedal housing 102 may be one or more structural features 108 providing strength and support to the pedal housing 102. The number, type, and location of the one or more structural features 108 should not be considered limiting. In certain embodiments, and as best illustrated in FIGS. 2B and 4 A, the one or more structural features 108 may be provided within the receiving area 109. In the embodiment illustrated, the one or more structural features 108 include a first structural feature 108a and a second structural feature 108b. In this example, the first structural feature 108a may be laterally offset from a central axis 110 of the pedal housing 102 in a first direction 112a, and the second structural feature 108b may be laterally offset from the central axis 110 of the pedal housing 102 in a second direction 112b. In these examples, the structural features 108a-b may provide strength to the pedal 100, particularly when the pedal 100 is subjected to a braking force from a user (e.g., by engaging the pedal 100 at or proximate to the top end 131).

[0041] As best illustrated in FIGS. 2A-3, 4A, and 5, the integrated brake pedal 100 further includes a shaft 104. In certain embodiments, the shaft 104 may define the axis 106 about which the pedal housing 102 and / or the integrated brake pedal 100 may rotate in use. Incertain embodiments, the integrated brake pedal 100 may be positionable (e.g., rotatable) between a first position and a second position. In various embodiments, the first position may be a braking position in which the brake is activated, and the second position may be a rest position in which the brake is not activated. Optionally the integrated brake pedal 100 is biased towards or into the rest position.

[0042] The shaft 104 extends through the pedal housing 102, and in various embodiments, the shaft 104 is at least partially (and / or fully) retained within the enclosed portion 206 of the receiving area 109. Bearings 133 may be provided on the shaft 104 to facilitate rotation of the pedal 100 about the shaft 104. In some embodiments, the shaft 104 may be inserted into the receiving area 109 through the first side 208 or the second side 210 of the pedal housing 102. In other embodiments, and as discussed with respect to FIGS. 8 and 9, the shaft 104 may be inserted into the receiving area 109 through the back side 105. In such embodiments, one or more retaining caps 835 may be selectively attached to the pedal housing 102 on the back side 105 to retain the shaft 104 within the receiving area 109.

[0043] In certain embodiments, the shaft 104 may generally extend from proximate the first side 208 to proximate the second side 210 of the housing. In some embodiments, the attachment feature 250 may be attached or fixed to the shaft 104 using various mechanisms or attachment means as desired. In other embodiments, the attachment feature 250 may be integral or monolithic with the shaft 104 such that the attachment feature 250 is considered a portion of the shaft 104.

[0044] The integrated brake pedal 100 may include one or more brake control features for controlling operation of the brake pedal 100, providing operational feedback of the brake pedal 100, and / or as otherwise desired. As mentioned, the one or more brake control features may be provided within the receiving area 109 of the integrated brake pedal 100. In certain embodiments, the one or more brake control features may include one or more return devices 213. Additionally, or alternatively, the one or more brake control features may include one or more mechanical stop features 204. Additionally, or alternatively, the one or more brake control features may include one or more position sensors 202. Various other brake control features and combinations thereof may be utilized as desired.

[0045] When the one or more return devices 213 are included, the one or more return devices 213 may counteract a rotational (or braking) force applied by the user and / or maybias and / or otherwise move the brake pedal 100. When the one or more mechanical stop features 204 are included, and as discussed in detail below, the one or more mechanical stop features 204 may limit rotation of the brake pedal 100 about the shaft 104. When the one or more position sensors 202 are included, and as discussed in detail below, the one or more position sensors 202 may detect a position or angular movement of the brake pedal 100 about the shaft 104.

[0046] In various embodiments, when the one or more return devices 213 may be various components or combinations of components suitable for counteracting a rotational (or braking) force applied by the user and / or for biasing the brake pedal 100. As non-limiting examples, the one or more return devices 213 may be one or more springs 212, other biasing members, and / or an actuated device. A non-limiting example of an actuated device as the one or more return devices 213 may include, but is not limited to, a motor and a gearbox which may be controlled electronically to provide a return of the pedal 100 to the rest position and / or to provide a proper feeling of the pedal (e.g., resistance to rotation) to the user when operated. Other devices or combinations of devices may be utilized as the one or more return devices 213 as desired.

[0047] In the embodiment illustrated, the one or more return devices 213 includes one or more springs 212. In various embodiments, the one or more springs 212 may be provided with the shaft 104 and within the receiving area 109. As mentioned, the one or more springs 212 may apply rotational force to the pedal housing 102 counteracting an applied braking force. In certain embodiments, the one or more spring 212 may bias the pedal housing 102 towards or into the rest position (e.g., illustrated in FIGS. 1 A-1B).

[0048] Optionally, the one or more springs 212 are provided within the enclosed portion 206 of the receiving area 109. Optionally, the one or more springs 212 are within the shaft 104. In certain embodiments, the one or more springs 212 may be coupled to the pedal housing 102 and the shaft 104 such that the springs 212 bias the pedal housing 102. In one non-limiting example, the one or more springs 212 may be coupled to the side support 115 of the pedal housing 102 and the shaft 104. In some cases, the one or more springs 212 may be coupled to the pedal housing 102 proximate to one side of the pedal housing 102 (e.g., the first side 208) and may be coupled to the shaft 104 proximate to the other side of the pedal housing 102 (e.g., the second side 210), although they need not in other embodiments. In other embodiments, the springs 212 may be coupled to the pedal housing 102 and shaft 104 atvarious locations and / or in various configurations as desired suitable to bias the pedal housing 102. The number of springs 212 should not be considered limiting. In certain embodiments, and as illustrated in FIGS. 2A-2B, for example, the at least one spring 212 may include a first spring 212a and a second spring 212b, although other suitable numbers (e.g., less than two or more than two) of springs 212 may be included in the shaft 104. In some embodiments, the second spring 212b is located concentric with respect to the first spring 212a. In embodiments with a plurality of springs 212, a spring force of one spring may be greater than, less than, or approximately the same as the spring force of another spring.

[0049] The one or more position sensors 202 may be various suitable sensors for detecting a position and / or motion of the brake pedal 100 and / or the shaft 104. In one non-limiting example, the one or more position sensors are angular position sensors for sensing the brake pedal angular motion or position. The one or more position sensors 202 are mounted or otherwise supported in the receiving area 109, and in certain embodiments, the one or more position sensors 202 are provided within the open portion 111 of the receiving area 109. Any number of position sensors 202 may be utilized, and in the embodiment illustrated, the integrated brake pedal 100 includes two positions sensors 202a, 202b. Similarly, the position sensors 202 may be provided at various locations in the receiving area 109 suitable for detecting motion or position. As a non-limiting example and as illustrated in FIGS. 4A-7, the first position sensor 202a may be positioned adjacent to the first structural feature 108a, and the second position sensor 202b may be positioned adjacent to the second structural feature 108b. When a plurality of position sensors are utilized, a plurality of channels for sensing the integrated brake pedal 100 may be provided. As a non-limiting example, the first position sensor 202a and the second position sensor 202b may provide at least four channels of sensing for the integrated brake pedal 100.

[0050] In certain embodiments, the one or more position sensors 202 may be geared to the shaft 104. In such embodiments, the integrated brake pedal 100 may additionally include at least sensor gears 402a, 402b for coupling the position sensors 202 to the shaft 104. The number of sensors gears 402 may generally correspond with the number of position sensors 202, although they need not in other embodiments. As illustrated, the sensor gears 402a, 402b may be positioned in the receiving area 109 of pedal housing 102. In certain embodiments, the sensor gear 402a may be positioned (e.g., at least indirectly) in mechanical contact with the shaft 104. The sensor gear 402b may be positioned (e.g., at least indirectly) in mechanicalcontact with the shaft 104. In some embodiments, the first portion 404 of the shaft 104 and the second portion 406 of the shaft 104 may be laterally offset from one another.

[0051] In certain embodiments, the integrated brake pedal 100 may include geared inserts 408 for coupling the sensor gears 402 with the shaft 104. The number of geared inserts 408 may correspond with the number of sensor gears 402, although it need not in other embodiments. In the embodiment illustrated, the integrated brake pedal 100 includes two geared inserts 408a, 408b. Each geared insert 408a, 408b is coupled to the shaft 104 and engaged with a corresponding sensor gear 402a, 402b. In various embodiments, the geared inserts 408a, 408b are keyed or otherwise connected to the shaft 104. In certain embodiments the geared inserts 408a, 408b extend through the slots 117 in the wall 113 to couple the position sensors 202 and sensor gears 402 in the open portion 111 of the receiving area 109 with the shaft 104 in the enclosed portion 206 of the receiving area 109.

[0052] In some embodiments, the sensor gears 402a, 402b optionally are anti-backlash gears for minimizing and / or eliminating backlash in the gearing between the sensor gears 402a, 402b and the geared inserts 408a, 408b. Optionally, a pre-load spring 119 may be coupled with the sensor gears 402a, 402b. When included, the pre-load biasing member or spring 119 may minimize and / or eliminate backlash in the gearing between the sensor gears 402a, 402b and the geared inserts 408a, 408b and / or between the geared inserts 408a, 408b and the shaft 104. The pre-load spring 119 may be connected to the first gear and to the second gear, and reacted against the pedal housing 102, wherein the pre-load spring is adjustable to set the preload force for operating the pedal to within a desired range.

[0053] In certain embodiments, the integrated brake pedal 100 may include the one or more mechanical stop features 204 for limiting rotation of the pedal housing 102 and / or controlling a range of motion. In some embodiments, one or more mechanical stop features 204 are provided on the shaft 104 within the receiving area 109; however, the number and location of the one or more mechanical stop features 204 should not be considered limiting. Optionally, the one or more mechanical stop features 204 may be adjustable. In the embodiment illustrated, the mechanical stop feature 204 extends from the shaft 104 and may engage portions of the receiving area 109 for limiting and / or defining a range of motion of the integrated brake pedal 100.

[0054] As mentioned, various other brake control features may be utilized with the pedal 100 as desired.

[0055] FIG. 7 is a diagram of an example of the integrated brake pedal 100. As illustrated in FIG. 7, a first end 702 of the first spring 212a optionally may be coupled to the shaft 104 at a first point 704 on the shaft 104. In such embodiments, the first point 704 may be laterally offset from the central axis 110 of the pedal housing 102 in the first direction 112a. A second end 706 of the first spring 212a optionally may be coupled to the first structural feature 108a. Additionally, a first end 708 of the second spring 212b optionally may be coupled to the shaft 104 at a second point 710 on the shaft 104 that is laterally offset from the central axis 110 of the pedal housing 102 in the second direction 112b. A second end 712 of the second spring 212b optionally may be coupled to the second structural feature 108b.

[0056] In some embodiments, and as illustrated in FIGS. 1 A-4A, the attachment feature 250 may be provided on and / or extend from one side of shaft 104 (either as a separate component or integral with the shaft 104). As examples, the attachment feature 250 may extend from the shaft 104 at the first side 208 and / or the second side 210. In such embodiments, depending on which side of the shaft 104 that the attachment feature 250 extends from, the brake pedal 100 may be considered a “left” brake pedal or a “right” brake pedal 100. In some embodiments, the brake pedal 100 may be considered a “universal” brake pedal in that the brake pedal 100 may be installed on either a left side or a right side of a shaft by changing the location of the attachment feature 250 to be on one side of the shaft 104 or the other side. In such embodiments, the components of the brake pedal 100 may or may not be mirrored when the brake pedal 100 is a “right” brake pedal or a “left” brake pedal.

[0057] FIGS. 8 and 9 illustrate another example of a brake pedal 800 that is substantially similar to the brake pedal 100 except that the attachment feature 250 extends from a modified shaft 104 at an intermediate location along the shaft 104 between opposing ends 837, 839 of the shaft 104. In FIG. 8, the springs 212 that may be within the shaft 104 have been omitted for clarity of the figure. In such embodiments, the attachment feature 250 again may be attached to the shaft 104 or be integral or monolithic with the shaft 104. In various embodiments, when the shaft 104 is assembled with the pedal housing 102, the attachment feature 250 may be on the back side 105 of the pedal housing 102 (e.g., opposite from where the user engages the pedal 800). In these embodiments, the shaft 104 with the attachment feature 250 at the intermediate location may have a profile preventing installation into thereceiving area 109 through the first side 208 or the second side 210 of the pedal housing 102. In such embodiments, the shaft 104 may be installed into the receiving area 109 from the back side 105. One or more retaining caps 835 may be attachable to the back side 105 of the housing 102 and retain the shaft 104 on the housing 102. Optionally, the bearings 133 may be retained by the retaining caps 835. The brake pedal 800 may otherwise include components similar to those illustrated with the brake pedal 100 but have been omitted from FIGS. 8 and 9 for clarity of the figures. In various embodiments, the brake pedal 800 with the attachment feature extending from the shaft 104 at the intermediate location may be a “universal” brake pedal and may not require mirroring of components. Stated differently, the entire integrated pedal 800 may be the same regardless of whether the pedal 800 is used as a left pedal or a right pedal.

[0058] As illustrated in FIGS. 1A-9, the integrated brake pedal may define a single, enclosed structure that both functions as a brake pedal while also housing various brake control features. As non-limiting examples, the shaft, at least one position sensor, and / or at least one mechanical stop feature may be positioned within the single, enclosed structure. The single, enclosed structure of the integrated brake pedal may allow simple maintenance, repair, and / or replacement of the integrated brake pedal with respect to a vehicle.

[0059] Additionally, the integrated brake pedal, or any component thereof, may include various metals or metallic elements as desired, including but not limited to aluminum, an aluminum alloy, titanium, a titanium alloy, nickel, a nickel alloy, brass, a brass alloy, steel, a steel alloys, stainless steel or a stainless-steel alloy, combinations thereof, or any other suitable metal or metallic alloy. In other non-limiting examples, the integrated brake pedal, or any component thereof, includes other types of metallic elements, such as titanium, zinc, and the like, or metallic alloys such as titanium alloys, zinc alloys, and the like. In some embodiments, some components (e.g., the pedal housing 102, the shaft 104, etc.) of the integrated brake pedal may include non-metallic elements such as rubber, polymer, plastics, and the like.

[0060] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Example” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These examples are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limitedto these examples but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0061] Example 1. An integrated brake pedal for a vehicle, the integrated brake pedal comprising: a pedal housing comprising a first side, a second side opposite the first side, and a receiving area between the first side and the second side; a shaft extending through the receiving area of the pedal housing from the first side to the second side, the shaft defining an axis of rotation of the integrated brake pedal and comprising a return device configured to apply rotational force to the pedal housing; a position sensor positioned within the receiving area of the pedal housing and configured to detect angular rotation of the shaft; and a mechanical stop feature within the receiving area of the pedal housing and configured to limit rotation of the pedal housing.

[0062] Example 2. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the pedal housing comprises a side support at the first side, and wherein the return device is coupled to the side support of the pedal housing at the first side and is coupled to the shaft proximate to the second side of the pedal housing.

[0063] Example 3. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the return device is within the shaft.

[0064] Example 4. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the return device is a spring, wherein the spring is a first spring, and wherein the shaft further comprises a second spring, wherein the second spring is configured to apply rotational force to the pedal housing, and wherein the first spring and the second spring are concentric with respect to one another.

[0065] Example 5. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the pedal housing further comprises a side support laterally offset from a central axis of the pedal housing, and wherein: a first end of the first spring is coupled to the shaft at a first point on the shaft laterally offset from a central axis of the pedal housing; a second end of the first spring is coupled to the side support; a first end of the second spring is coupled to the shaft at a second point on the shaft laterally offset from the central axis of the pedal housing; and a second end of the second spring is coupled to the side support.

[0066] Example 6. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the integrated brake pedal is rotatable between a braking position and a rest position, and wherein the return device biases the pedal housing to the rest position.

[0067] Example 7. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the return device is within an enclosed portion of the receiving area.

[0068] Example 8. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the pedal housing comprises a front side and a back side, wherein the front side defines an engagement surface for receiving an input from a user, and wherein the receiving area is recessed in the back side of the pedal housing.

[0069] Example 9. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the receiving area comprises an enclosed portion and an open portion.

[0070] Example 10. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the position sensor is within the open portion and the shaft is within the enclosed portion.

[0071] Example 11. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the position sensor is coupled with the shaft via a geared insert extending through a slot defined in the pedal housing.

[0072] Example 12. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the mechanical stop feature is on the shaft.

[0073] Example 13. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the position sensor is a first position sensor, and a spring as the return device, wherein the spring is a first spring, wherein the integrated brake pedal further comprises a second position sensor and a second spring, wherein the second spring is positioned concentric with respect to the first spring.

[0074] Example 14. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, further comprising: a first gear coupled to the first position sensor; a second gear coupled to the second position sensor; a first geared insertcoupled to the shaft and engaged with the first gear; a second geared insert coupled to the shaft and engaged with the second gear; and a pre-load spring connected to the first gear and to the second gear, wherein the pre-load spring is adjustable to apply pre-load on the pedal housing and in response to the pedal housing receiving a brake-applying force.

[0075] Example 15. A braking system for an aircraft, the braking system comprising: the integrated brake pedal of any of the preceding or subsequent examples or combination of examples; and a second shaft coupled to the integrated brake pedal, wherein the second shaft couples the integrated brake pedal of any of the preceding or subsequent examples or combination of examples to the aircraft.

[0076] Example 16. An integrated brake pedal for a vehicle comprising: a pedal housing comprising a front side, a back side, and a receiving area defined in the back side of the pedal housing; and a brake control feature within the receiving area of the pedal housing, wherein the brake control feature comprises at least one of a mechanical stop feature, a return device, or a position sensor.

[0077] Example 17. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, wherein the receiving area comprises an open portion and an enclosed portion, wherein the position sensor is within the open portion, and wherein the return device is within the enclosed portion.

[0078] Example 18. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples further comprising a shaft extending through the receiving area, wherein the shaft defines an axis of rotation of the integrated brake pedal, and wherein the return device is within the shaft and concentric with the shaft.

[0079] Example 19. An integrated brake pedal for a vehicle comprising: a pedal housing comprising a front side, a back side, and a receiving area defined in the back side of the pedal housing, the receiving area comprising an open portion and an enclosed portion; a shaft extending through the enclosed portion of the receiving area of the pedal housing, wherein the shaft defines an axis of rotation of the integrated brake pedal; and a spring within the shaft and concentric with the shaft, wherein the spring is configured to apply rotational force to the pedal housing.

[0080] Example 20. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, further comprising a mechanical stop feature and a position sensor within the receiving area.

[0081] Example 21. The integrated brake pedal of any of the preceding or subsequent examples or combination of examples, further comprising an attachment feature for attaching the integrated brake pedal to a shaft, wherein the attachment feature is integral with the shaft and extends from the shaft at an intermediate location between opposing ends of the shaft and on a back side of the pedal housing.

[0082] Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.

[0083] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the FIG. (or figures) to which the components and directions are referencing. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, or gradients thereof, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention, and does not pose a limitation on the scope of the invention unless otherwise claimed. Nolanguage in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0084] As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained.

[0085] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. The invention is susceptible to various modifications and alternative constructions, and certain shown exemplary embodiments thereof are shown in the drawings and have been described above in detail. Variations of those preferred embodiments, within the spirit of the present invention, may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, it should be understood that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

[0086] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Claims

CLAIMSThat which is claimed is:

1. An integrated brake pedal for a vehicle, the integrated brake pedal comprising: a pedal housing comprising a first side, a second side opposite the first side, and a receiving area between the first side and the second side; a shaft extending through the receiving area of the pedal housing, the shaft defining an axis of rotation of the integrated brake pedal and comprising a return device configured to apply rotational force to the pedal housing; a position sensor positioned within the receiving area of the pedal housing and configured to detect angular rotation of the shaft; and a mechanical stop feature within the receiving area of the pedal housing and configured to limit rotation of the pedal housing.

2. The integrated brake pedal of claim 1, wherein the pedal housing comprises a side support at the first side, and wherein the return device is coupled to the side support of the pedal housing at the first side and is coupled to the shaft proximate to the second side of the pedal housing.

3. The integrated brake pedal of claim 1, wherein the return device is within the shaft.

4. The integrated brake pedal of claim 1, wherein the return device is a spring, wherein the spring is a first spring, and wherein the shaft further comprises a second spring, wherein the second spring is configured to apply rotational force to the pedal housing, and wherein the first spring and the second spring are concentric with respect to one another.

5. The integrated brake pedal of claim 4, wherein the pedal housing further comprises a side support laterally offset from a central axis of the pedal housing, and wherein: a first end of the first spring is coupled to the shaft at a first point on the shaft laterally offset from a central axis of the pedal housing; a second end of the first spring is coupled to the side support; a first end of the second spring is coupled to the shaft at a second point on the shaft laterally offset from the central axis of the pedal housing; anda second end of the second spring is coupled to the side support.

6. The integrated brake pedal of claim 1, wherein the integrated brake pedal is rotatable between a braking position and a rest position, and wherein the return device biases the pedal housing to the rest position.

7. The integrated brake pedal of claim 1, wherein the return device is within an enclosed portion of the receiving area.

8. The integrated brake pedal of claim 1, further comprising an attachment feature for attaching the integrated brake pedal to a shaft, wherein the attachment feature is integral with the shaft and extends from the shaft at an intermediate location between opposing ends of the shaft and on a back side of the pedal housing.

9. The integrated brake pedal of claim 1, wherein the receiving area comprises an enclosed portion and an open portion.

10. The integrated brake pedal of claim 9, wherein the position sensor is within the open portion and the shaft is within the enclosed portion.

11. The integrated brake pedal of claim 10, wherein the position sensor is coupled with the shaft via a geared insert extending through a slot defined in the pedal housing.

12. The integrated brake pedal of claim 1, wherein the mechanical stop feature is on the shaft.

13. The integrated brake pedal of claim 1, wherein the position sensor is a first position sensor, wherein the return device is a spring, wherein the spring is a first spring, wherein the integrated brake pedal further comprises a second position sensor and a second spring, wherein the second spring is positioned concentric with respect to the first spring.

14. The integrated brake pedal of claim 13, further comprising: a first gear coupled to the first position sensor;a second gear coupled to the second position sensor; a first geared insert coupled to the shaft and engaged with the first gear; a second geared insert coupled to the shaft and engaged with the second gear; and a pre-load spring connected to the first gear and to the second gear, wherein the preload spring is adjustable to apply pre-load on the pedal housing and in response to the pedal housing receiving a brake-applying force.

15. A braking system for an aircraft, the braking system comprising: the integrated brake pedal of claim 1; and a second shaft coupled to the integrated brake pedal, wherein the second shaft couples the integrated brake pedal of claim 1 to the aircraft.

16. An integrated brake pedal for a vehicle comprising: a pedal housing comprising a front side, a back side, and a receiving area defined in the back side of the pedal housing; and a brake control feature within the receiving area of the pedal housing, wherein the brake control feature comprises at least one of a mechanical stop feature, a return device, or a position sensor.

17. The integrated brake pedal of claim 16, wherein the receiving area comprises an open portion and an enclosed portion, wherein the position sensor is within the open portion, and wherein the return device is within the enclosed portion.

18. The integrated brake pedal of claim 16 further comprising a shaft extending through the receiving area, wherein the shaft defines an axis of rotation of the integrated brake pedal, and wherein the return device is within the shaft and concentric with the shaft.

19. An integrated brake pedal for a vehicle comprising: a pedal housing comprising a front side, a back side, and a receiving area defined in the back side of the pedal housing, the receiving area comprising an open portion and an enclosed portion; a shaft extending through the enclosed portion of the receiving area of the pedal housing, wherein the shaft defines an axis of rotation of the integrated brake pedal; anda spring within the shaft and concentric with the shaft, wherein the spring is configured to apply rotational force to the pedal housing.

20. The integrated brake pedal of claim 19, further comprising a mechanical stop feature and a position sensor within the receiving area.

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