Machine element or mechanism – Control lever and linkage systems – Elements
Reexamination Certificate
2000-09-22
2003-02-04
Kim, Chong H. (Department: 3682)
Machine element or mechanism
Control lever and linkage systems
Elements
Reexamination Certificate
active
06513407
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention is directed to a control lever assembly for a vehicle, and more particularly to using a hydroformed tubular member.
Lever assemblies are used in conventional motor vehicles for brakes, clutches, accelerators and emergency brakes. Many of these lever constructions are fabricated assemblies and typically consist of a bent steel bar with apertures and bushings at one end for receiving a pin for pivotal attachment to the vehicle and a stamped sheet metal foot plate at the other end. A foot pad, bushing and bracketry are attached to the steel bar to form a fabricated assembly. Additionally, the lever assembly may have tabs welded to it for the actuation of switches, the attachment of return springs and other similar devices. Examples of lever assemblies are disclosed in U.S. Pat. Nos. 4,356,740, 5,044,223, and 5,078,024. These prior art assemblies are relatively heavy, complex and expensive to manufacture and require welding or equivalent joining operations which can reduce the durability and reliability of the lever assembly.
A lightweight pedal mechanism formed by hydroforming is disclosed in U.S. Pat. No. 5,435,205. The pedal mechanism is made from a single length of extruded, thin-walled, round cross-section aluminum tubing. It consists of an upper clevis portion, a central portion and a lower foot engaging section. The clevis section has opposed apertures for receiving a bushing. Directly above the aperture is a cut-out section in communication with the extreme end of the side walls and with the apertures in the side walls. The bushing has an outer diameter with grooves or notches. This prevents the bushing from moving out of the clevis section in a radial direction. The foot engaging section is formed from a lower section that is bent in a plane that is about at a right angle relative to the length of the main body portion. Because the foot engaging section extends at a right angle relative to the main body portion, the pedal is not compact. Also, the bushing must be inserted separately into the apertures in the clevis section.
This design has not been extensively adopted for motor vehicle use in spite of its purported advantages. Thus, there is still a need for an improved lever assembly that overcomes the limitations of the above design and provides a light-weight, inexpensive, compact, easy to manufacture, and integrated, longitudinally oriented lever assembly.
SUMMARY OF THE INVENTION
The present invention provides a lever assembly consisting of a one piece metal tubular member having an integrally formed first end, an integrally formed opposite second end, and an integrally formed center section between the first and second ends, a free end integrally formed of the second end and a clevis portion integrally formed within the first end. The clevis portion has a pair of spaced apart walls and an integral projection extending away from one of the pair of spaced apart walls.
It is an object of the present invention to provide a lever assembly which can be used for a variety of applications, including brakes, clutches, accelerator devices or emergency brakes in a vehicle, and which is light weight, inexpensive, easy to manufacture and integrates a jointless projection to receive and retain a bushing therein.
It is a further object of the present invention to provide a longitudinal lever assembly which is formed by hydroforming or a similar process and in which the integral projections are hydropierced to form an aperture which receives a bushing pin therein and which is inexpensive and easy to manufacture.
It is still a further object of the present invention to provide a longitudinal lever assembly with a central portion which has an integral projection and a structural configuration which permits the integration of switches, gauges, mounting devices or actuator rods and yet is easy and inexpensive to manufacture.
It is still another object of the present invention to provide a lever assembly with an integral projection and a pedal section with a pair of spaced apart portions forming a planar surface, an intermediate portion which is below the planar surface supporting the spaced apart portions and which is easy and inexpensive to manufacture.
These and other objects of the invention will become apparent from a consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
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Increasing The Hydroforming Knowledge BaseAutomotive Engineering International / Feb. 2000, pp 19, 20-22.
Kim Chong H.
Lattimore & Tessmer, Inc.
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