Electrical connectors – With relatively guided members and intermediate pliable... – Relatively movable about axis
Reexamination Certificate
1999-07-26
2001-04-10
Paumen, Gary F. (Department: 2833)
Electrical connectors
With relatively guided members and intermediate pliable...
Relatively movable about axis
C439S015000
Reexamination Certificate
active
06213797
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a clockspring connector for enclosing electrical conductor cables. The invention more particularly concerns the clockspring connector electrically connects a rotatable electric device with a stationary electric device.
2. Discussion of the Background
While the present invention may have multiple applications, the most prevalent is for use in automobiles. An increasing number of automobiles have airbag crash systems. An airbag is typically located on the steering wheel facing the driver. The airbag must be in continuous electrical connection with sensors in the car body. The sensors provide an electrical signal to the airbag crash assembly which instantly inflates the airbag in the event of a crash. Accordingly, there is a need for an electrical connection between the rotatable portion of the airbag assembly which is mounted to the steering wheel, and the remaining portion of the assembly which is in a stationary position in the car body. Electrical connections between rotatable and stationary parts are well known. Typically, an electrical brush rests upon a conductive ring, with one of the parts being rotatable to provide such rotatable electrical connection. However, there is a risk, particularly during the impact of an accident, of a transient failure of electrical connection with a brush and ring system which result in failure of the entire airbag system crash assembly.
Additionally, airbags are being incorporated into seat belt chest harnesses. Thus, an electrical connection is needed between the stationary portion of the vehicle and the translating seat belt chest harness which is wound and un-wound around a rotating return axis.
Accordingly, a clockspring connector has previously been developed, comprising an outer housing, a rotor member and a multiple of intermediate housing members for enclosing and connecting the members; the housing and rotor member rotatably associated with one another at a plurality of bearing surfaces. A “clockspring” is located inside the interconnector. The clockspring of prior art devices includes a single flat conductor cable having its ends conductively attached to conductor wires which pass out of the interconnector to unite the airbag to the sensing device. For example, U.S. Pat. No. 5,061,195 discloses a clockspring housing and assembly having a single flat conductor cable therein.
It has also been known in the art to reduce the length of the flat conductor cable in order to reduce cost and needed space within the clockspring housing. For example, U.S. Pat. No. 5,277,604 incorporates an assembly of at least eight rollers and turned-back portions of the flat conductor cable within the clockspring housing to decrease the length of the flat cable and also prevent buckling and enhance reliability and smooth rotation of the clockspring connector. Such a design requires a complex and expensive system of mounting the rollers. Such a design may be expensive and, as well, only accommodates a single flat conductor cable.
The use of a pair of conductor cables was disclosed in U.S. Pat. No. 3,763,455. The conductor cables were carried by an assembly of twenty spacers or rollers. This design also requires a multiplicity of parts, including numerous rollers which add to the assembly time and costs of the device.
As more controls are mounted on the steering wheel, more conductors are required to pass multiple electrical signals through the clockspring connector. Prior art clocksprings have included conductor cables having up to six conductors in each flat cable. The excess of six conductors is limited by the limited width of the flat conductor cable and the processing methods of manufacturing the flat cable. Accordingly, there is needed a clockspring connector which can accommodate more than six conductors.
Still further, assembling clocksprings is a laborious and costly process that is prone to error. In particular, the known art requires that the clockspring be assembled from an assortment of components that guide flat ribbon cables in sync with the rotation of the steering wheel. Assembling the various components individually into a clockspring is a tedious and labor intensive process.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide for a clockspring that may readily be assembled and manufactured.
It is still another object of the invention to provide for an integrated carrier assembly having a frame and which easily assembles within a steering wheel.
It is another object of the present invention to provide a clockspring connector having a minimal amount of moving parts.
It is a further object of the present invention to provide a clockspring connector having flat conductor cable of minimal length.
It is another object of the present invention to provide a clockspring having a freely and independently rotating carrier member.
It is a further object of the present invention to provide a clockspring connector that reduces vibration of the flat conductor cable by use of a compliant roller member.
It is yet another object of the invention to provide a durable clockspring.
The above objects and advantages are provided by a clockspring connector comprising a housing defining a chamber extending therethrough. A carrier member positioned within the chamber having a hard roller member and a plurality of complaint roller members. A flat conductor cable being carried by the carrier member. The flat conductor cable having a turned-back portion associated with the hard roller member. A hub having an inner diameter exit cavity for receiving the flat conductor cable. The housing member receives the hub, the carrier member is mounted on the hub, and a cover encloses the carrier member and flat flexible cable within the housing. The cover having an outer diameter exit cavity.
In an alternative embodiment of the invention, the clockspring provides for the housing to include a carrier assembly rotatably mounted thereto. The housing itself includes a fixed cover and a base that define a chamber. The carrier assembly preferably comprises a frame having one or more rollers that rotate independently. Within the housing, an inner diameter region is concentrically defined by a hub and the frame, and an outer diameter region is concentrically defined by the frame and the housing. The first and second flat ribbon cables are variably distributed to encircle the hub along either the inner or outer diameter regions. The flat ribbon cables pass and turn-back through the rollers of the frame, so that the portions of each flat ribbon cables located in the inner and outer diameter regions move in opposite directions. Each flat ribbon cable includes a slack length that passes through a corresponding roller or roller pair to vary the distribution of the flat ribbon cable between the inner and outer diameter. A hard roller member being positioned at a concave surface of the turned-back portion of one of the flexible flat cables and a compliant roller member being positioned at a convex surface of the flexible flat cable at the turned-back portion. The first and second flat ribbon cables interconnect to an inner backbone, as incorporated by previous embodiments, that is received by the base and accessible to each flat ribbon cable from the inner diameter region. An outer backbone is also accessible to each flat ribbon cable along the outer diameter region, such that the flat ribbon cables may interconnect the inner and outer backbone within the clockspring. In this way, rotation of the inner backbone causes the flat ribbon cables to contact and rotate the integrated carrier assembly. In particular, the slack length of each flat ribbon cable may contact a roller and rotate the integrated carrier assembly in conjunction with the intake or outtake of flat ribbon cable. Preferably, the slack length of each flat ribbon cable may contact one or the other roller forming a roller pair that receives each flat ribbon cable, thereby forcing the integrated carrier assembly to rotate in ei
Best Gary R.
Bolen Patrick A.
Kovach Karl D.
Methode Electronics Inc.
Newman David L.
Paumen Gary F.
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