U.S. patent application number 10/143239 was filed with the patent office on 2003-01-09 for construction and process of all-plastic cables for power and manual driving applications.
Invention is credited to Ashtiani, Mansour, He, Xinhua (Sam).
Application Number | 20030005681 10/143239 |
Document ID | / |
Family ID | 26840822 |
Filed Date | 2003-01-09 |
United States Patent
Application |
20030005681 |
Kind Code |
A1 |
He, Xinhua (Sam) ; et
al. |
January 9, 2003 |
Construction and process of all-plastic cables for power and manual
driving applications
Abstract
A plastic driving cable for attachment and use in driving
systems. The plastic driving cable is comprised of an all-plastic
inner core, with or without an outer jacket, and all-plastic molded
end fittings. The inner core has a configuration of interwoven or
bundled fibers of high performance polymer providing a cable of
increased strength and flexibility that fits a smaller bending
radius and has high performance at low temperatures. The outer
jacket comprises a non-metallic material that surrounds the inner
core providing improved performance at low temperatures.
Inventors: |
He, Xinhua (Sam); (Troy,
MI) ; Ashtiani, Mansour; (Beverly Hills, MI) |
Correspondence
Address: |
KATHRYN A. MARRA
DELPHI TECHNOLOGIES, INC.
Legal Staff Mail Code: 480-414-420
P.O. Box 5052
Troy
MI
48007-5052
US
|
Family ID: |
26840822 |
Appl. No.: |
10/143239 |
Filed: |
May 10, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60302397 |
Jul 2, 2001 |
|
|
|
Current U.S.
Class: |
57/210 ; 57/202;
57/216; 87/6; 87/8 |
Current CPC
Class: |
D04C 1/12 20130101; D04C
1/02 20130101 |
Class at
Publication: |
57/210 ; 57/202;
57/216; 87/6; 87/8 |
International
Class: |
D02G 003/36; D02G
003/02; D02G 001/00; D04C 001/00 |
Claims
What is claimed is:
1. A driving cable comprising: an inner core member; and a
plurality of fibers, said fibers being comprised of non-metallic
materials and forming said inner core member.
2. The driving cable of claim 1, wherein the plurality of fibers
are comprised of a liquid crystal polymer.
3. The driving cable of claim 1, wherein the fibers are braided in
an interwoven fashion to form said inner core member.
4. The driving cable of claim 1, wherein the fibers are twisted
together to form said inner core member.
5. The driving cable of claim 1, wherein the fibers are positioned
uni-directionally as a bundle, to form said inner core member.
6. The driving cable of claim 1 further comprising an outer jacket
in contact with an outer surface of said inner core.
7. The driving cable of claim 6, wherein the outer jacket is
comprised of a layer of braided non-metallic fibers.
8. A driving cable assembly comprising: an inner core member
comprised of a plurality of non-metallic fibers; a first end
portion and a second end portion of said inner core member; and a
first end-fitting member comprised of non-metallic material, said
first end fitting member being located adjacent to said first end
portion of said inner core member.
9. The driving cable assembly of claim 7, wherein said first end
portion of said inner core member further comprises a knot with
said knot being positioned inside first end fitting.
10. The driving cable assembly of claim 8, wherein said first end
portion of the inner core member further comprises a loop, with
said loop extending outside of said first end fitting.
11. The driving cable assembly of claim 7, wherein said first end
portion of the inner core member further comprises a core tail
extending outside of said first end fitting member.
12. The driving cable assembly of claim 7, wherein the first end
fitting member further comprises a hole for attachment of a device
therein.
13. The driving cable of claim 7 further comprising a second end
fitting member, said second end fitting member being located
adjacent to said second end portion of said inner core member
14. The driving cable of claim 7 further comprising a nonmetallic
outer jacket surrounding the inner core member.
15. A method for making an improved driving cable assembly
comprising: forming an inner core member comprised of a plurality
of nonmetallic fibers, said inner core member having a first end
portion and a second end portion; providing a first end-fitting
member, said first end fitting member being comprised of a
non-metallic material; and attaching said first end fitting member
in a position adjacent to said first end portion of said inner core
member.
16. The method of claim 14, wherein the step of forming the inner
core member further comprises: braiding said plurality of
non-metallic fibers.
17. The method of claim 14, wherein the step of forming said inner
core member further comprises: twisting said plurality of
non-metallic fibers.
18. The method of claim 14, wherein the step of forming said inner
core member further comprises: positioning the plurality of
non-metallic fibers in a uni-directional fashion.
18. The method of claim 14 further comprising: locating a
non-metallic outer jacket surrounding the inner core member.
19. The method of claim 14, wherein the step of attaching said
end-fitting member is by over-molding.
20. The method of claim 14 further comprising: positioning a second
end fitting member adjacent to said second end portion of said
inner core member.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims priority from U.S. Provisional
Application Serial No. 60/302,397 entitled "Construction and
Process of All-Plastic Cables for Power and Manual Driving
Applications," filed Jul. 2, 2001.
TECHNICAL FIELD
[0002] The present invention relates generally to driving cables
and more specifically to driving cables for power and manual
driving applications.
BACKGROUND OF THE INVENTION
[0003] Driving cables are often used in power and manual products
for automotive systems, and are typically constructed of a metal
wire core with metal end fittings. The metal wire core and the end
fittings are usually constructed of steel or stainless steel.
Moreover, some metal wire cores have been coated with an outer
layer of plastic or elastomer to form an outer jacket. One drawback
of this type of cable assembly is that at low temperatures, the
outer jacket flexibility is reduced. Also, these prior steel
cables, with or without an outer jacket, lack the bending strength
and flexibility required for use with the smaller pulleys that are
needed to accommodate smaller packaging requirements. When use at
smaller bending radius, the metal cable introduces higher bending
stress. Thus, there exists a need for a driving cable which can
perform at lower temperatures and also possesses the strength and
flexibility required for use with smaller bending radius.
[0004] In automotive systems, a driving cable is used in a variety
of applications including sliding doors, lift gates, hood and trunk
openers, and windows and latches. Thus, the driving cables need
greater flexibility and bending strength than the typical metal
cable. Also, current metal cables often create vibrations and noise
in use. Thus, there is a need for a driving cable that reduces the
noise and vibrations inherent with swaged metal cables, while
simplifying the driving systems and increasing performance.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide an
improved driving cable for use with manual and automatic driving
systems.
[0006] It is another object of the present invention to provide a
driving cable with increased bending strength and flexibility.
[0007] It is another object of the present invention to provide a
driving cable that performs with less noise and vibrations.
[0008] It is still another object of the present invention to
provide a driving cable that is lighter in weight and provides
improved performance.
[0009] It is a further object of the present invention to provide a
method for constructing an improved driving cable for use within
manual and automatic driving systems.
[0010] In accordance with the above and other objects of the
present invention, an improved driving cable is disclosed. The
driving cable includes an inner core that is comprised almost
entirely of a plastic material. The inner core has two end portions
which are attached in unique ways to end fittings. The inner core
is comprised of polymer fibers which are configured to provide the
necessary strength. The inner core may include a surrounding outer
jacket that is also formed of a non-metallic material. The
disclosed cable provides improved performance at low temperatures,
as well as increased flexibility and strength.
[0011] Further objects and advantages of the invention will be
apparent from the following description and appended claims,
reference being made to the accompanying drawings forming a part of
the specification, wherein like reference characters designate
corresponding parts in several view.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a partial cross-sectional perspective view of a
driving cable in accordance with the present invention;
[0013] FIG. 2A illustrates a driving cable end fitting
configuration with a knot and a loop in accordance with a preferred
embodiment of the present invention;
[0014] FIGS. 2B and 2C each illustrate a driving cable end fitting
configuration with a loop portion in accordance with an embodiment
present invention;
[0015] FIGS. 3A and 3B each show a portion of a driving cable with
an end fitting configuration that has a knot and a tail extending
inside of the end fitting member in accordance with a preferred
embodiment of the present invention;
[0016] FIGS. 3C and 3D illustrate additional end fitting
configurations for a driving cable that have a core tail extending
outside of the end fitting member in alternate embodiments of the
present invention;
[0017] FIGS. 4A and 4B are illustrations of a driving cable with an
end fitting member that has an opening in two different embodiments
of the present invention; and
[0018] FIG. 4C is a cross-sectional view of a portion of the end
fitting member shown in FIGS. 4A and 4B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The present invention refers to a plastic driving cable
particularly for use with manual and automatic driving systems.
Although the plastic cable is preferably utilized in connection
with automotive systems, it will be understood that it can have a
variety of other uses and applications. Therefore, the present
invention is not limited to use only in automotive or driving
systems. The terms "plastic" or "all-plastic` as used herein, when
referring to the driving cable, means that the driving cable is
comprised substantially of a plastic or polymeric material.
However, the driving cable may contain other materials so long as
it achieves the objects of the present invention.
[0020] Turning first to FIG. 1, there is shown a partial
cross-sectional perspective view of a preferred plastic cable which
is referred to generally to be the reference numeral 10. The
plastic cable 10 has an inner core member 16 preferably constructed
of high-performance fibers 15. The fibers 15 are preferably
intertwined to provide increased strength and flexibility over
conventional metal cables. The inner core fibers 15 may
alternatively be braided, twisted or uni-directed bundles of yarn,
strand or threadline, as desired. In a preferred embodiment, the
inner core member 16 is comprised of high performance polymer
fibers 15 such as, TM liquid crystal polymer Vectran.TM., aromatic
polyester, aromatic polyamide, and ultra-high molecular weight
polyethylene for high tensile strength and better flexibility. A
variety of other materials, including synthetic fibers of
polyamide, such as Nylon 6 and Nylon 66, polyester, liquid crystal
polymer, and compositions of polyprophylene, and polyethylene may
comprise the inner core member 16 to achieve the desired tensile
strength and flexibility. The fibers 15 may alternatively be formed
of natural fibers, such as cotton, wool, silk, jute and various
other materials. The configuration and material of the fibers 15
can vary and will be within the knowledge of those skilled in the
art.
[0021] The inner core member 16 has a first end portion 11 and a
second end portion. The inner core member 16 may be formed in a
variety of configurations. The inner core member 16 may be
comprised of continuous filament fibers which can be uni-directed,
twisted, or braided yarn, strand, or threadline. The fashion in
which the fibers are interwoven affects the strength of the driving
cable 10. Preferably, a braided inner core member 16 often provides
the bending strength and flexibility for high load applications,
such as power sliding doors, as well as other automotive and
non-automotive applications. Generally, inner core members 16
constructed of uni-directed fibers may be less costly to produce
than the braided inner core member. The uni-directed inner core
member may be applicable for automotive window systems. An
all-plastic core with a twisted inner core member may exhibit a
variety of applications depending in part upon the twist angle and
frequency. As the twist angle and frequency increase, the inner
core member is more solid and less flexible than an inner core
member with a lower twist angle and less twist frequency. Although
the twisted inner core member may be complex to construct, this
inner core configuration may offer a wide range of
applications.
[0022] Depending on the particular application of the driving cable
10, the exterior surface 16A of the inner core member 16 may be
further treated with a lubricant layer shown as reference number 18
and/or environmental protection coating 19. In a preferred
embodiment, the exterior surface 16A of the inner core member 16 is
coated with a dry lubricant, in order to allow the driving cable to
slide more easily over a mechanism, such as a pulley, to decrease
the wear on the cable and the mating components during use. It will
be understood, the driving cable is typically movable between a
retracted and unretracted position.
[0023] The inner core member 16 preferably has an outer jacket 12
disposed therearound. The interior surface 12B of the outer jacket
12 is preferably in contact with the exterior surface 16A of the
inner core member 16. A lubricant layer 18' and/or environmental
protection layer 19' may be applied between the exterior surface
16A of the inner core member 16 and the interior surface 12B of the
outer jacket 12.
[0024] The outer jacket 12, as viewed in FIG. 1 may be an outlayer
of braided fibers 14, either in yarn, strands or threadline. The
composition of these fibers 14 may be chosen from the materials
which comprise the inner core fibers 15, as discussed above, which
preferrably include high performance polymer fibers 15 such as,
liquid crystal polymer Vectran.TM., aromatic polyester, aromatic
polyamide, and ultra-high molecular weight polyethylene for high
tensile strength and better flexibility. A variety of other
materials, including synthetic fibers of polyamide, such as Nylon 6
and Nylon 66, polyester, liquid crystal polymer, and compositions
of polyprophylene, and polyethylene may comprise the outlayer of
braided fibers 14 to achieve the desired tensile strength and
flexibility. The fibers 14 may alternatively be formed of natural
fibers, such as cotton, wool, silk, jute and various other The
outer jacket 12 may also be comprised of a coating layer of
plastic, including but not limited to a nylon composition or a
liquid crystal polymer, such as Vectra.TM.. Alternatively, the
outer jacket 12 can be comprised of an elastomer, such as rubber or
thermoplastic olefin. Again, the precise selection of the material
is within the knowledge of those of ordinary skill in the art.
However, it is preferred that the outer jacket 12 be comprised of a
non-metallic material.
[0025] An advantage of including an outer jacket 12 in the
construction of the plastic driving cable 10, is that the diameter
of the plastic driving cable 10 can be adjusted to a variety of
desirable dimensions. The materials that comprise the outer jacket
12 may be less costly than the configuration of high performance
polymers that are preferably used to construct the inner core
member 16, and can be relatively easily applied to make a plastic
driving cable 10 of a precise diameter. Another advantage of an
all-plastic driving cable 10 with an outer jacket 12 is that the
outer jacket may separate from the inner core member 16 at the
exterior surface 16A of the inner core member 16, if so desired.
The relative movement between the inner core member 16 and outer
jacket 12 can reduce the bending stress upon the cable and increase
the cable flexibility. If a preferred application requires, the
outer jacket 12 may be completely separated and removed from the
inner core member 16. Coating the exterior surface 16A of the inner
core 16 with a dry lubricant eases the movement between the inner
core member 16 and outer jacket 12, and, if required, allows the
inner core member 16 and outer jacket 12 to separate more
efficiently.
[0026] As with the inner core member 16, the exterior surface 12A
of the outer jacket 12 may be coated with a lubricant 18 and/or
environmental protection coating 19, depending upon the application
in order to increase the life span and performance of the driving
cable 10.
[0027] Turning now to FIG. 2A which illustrates a driving cable
assembly 20A having an end-fitting configuration 21A. The
end-fitting configuration 21A in this embodiment includes a loop 23
and a knot 26. An end-fitting member 24 is comprised of molded
plastic and may be formed into a variety of shapes, such as oval,
cylindrical and square, as required by the desired application. In
the preferred embodiment shown in FIG. 2A, the driving cable 22
forms a spliced eye loop 23 which may be a connecting site for the
cable assembly 20A to connect with another device. The cable knot
26 may be preformed into a variety of shapes capable of providing
resistance and thereby increasing the strength of the driving cable
20A. The knot 26 is preferably located within the end fitting 24
with the loop 23 extending outside of the end fitting 24 opposite
the remainder of the driving cable 22. While only one end fitting
is shown and described, it will be appreciated that the other end
fitting preferably has the same configuration.
[0028] FIG. 2B illustrates another embodiment of the driving cable
assembly 20B having an end-fitting configuration 21B. In this
embodiment, the end fitting configuration 21B is comprised of an
end fitting member 24 and a spliced eye loop 23. The driving cable
22 has a core tail 25 which is formed or cramped within the end
fitting member 24.
[0029] Turning to FIG. 2C which illustrates another embodiment of
the driving cable assembly 20C having an end-fitting configuration
21C. The end fitting member 24 is positioned so that the driving
cable 22 forms a spliced eye loop 23 and the core tail 25 extends
outside of the end fitting member 24 opposite the loop 23. By
extending the core tail 25 outside of the end fitting member 24
this embodiment of the driving cable assembly 20C provides
increased strength and versatility of applications.
[0030] Turning now to FIGS. 3A and 3B another embodiment of the
present invention is shown. FIG. 3A illustrates a driving cable
assembly 30A having a different end fitting configuration 31A. FIG.
3A depicts a driving cable 34 and a knot 36. In this embodiment,
the knot 36 is located within an end fitting member 38. The knot 36
has a core tail 35 extending therefrom. The core tail 35 is also
located within the end fitting member 38. The end fitting member 38
is positioned perpendicularly to the length of the driving cable
34. FIG. 3B illustrates another embodiment of a driving cable
assembly 30B. This particular embodiment includes a driving cable
34 and a knot 36. The knot 36 is located within an end fitting
member 38 positioned on the driving cable 34. The knot 36 has a
core tail 35 extending therefrom. In this end-fitting configuration
31B, the end fitting member 38 is positioned lengthwise with the
driving cable 34.
[0031] FIG. 3C illustrates another embodiment of a driving cable
assembly 30C having an end-fitting configuration 31C. In this
embodiment, a driving cable 34 has an end fitting member 38
positioned perpendicularly to the driving cable 34. The driving
cable 34 has a core tail 35 extending therefrom. The core tail 35
further extends outside of the end-fitting member 38. Further, in
FIG. 3D, an alternate driving cable assembly 30D is shown. In this
embodiment, an end fitting configuration 31D is comprised of a
driving cable 34 with an end fitting member 38 positioned
lengthwise along the end of the driving cable 34. The driving cable
assembly 30D, the driving cable 34 has a core tail 35 extending
therefrom. The core tail 35 further extends outside of the
end-fitting member 38.
[0032] The length of the core tail 25, 35 may vary from being
hidden inside the end fitting 24, 38 to extending outside of the
end fitting 24, 38. The precise length and position of the core
tail 25, 35 will correspond to the requirements of the desired
application.
[0033] As shown in FIG. 4A, a driving cable assembly 40 with an end
fitting configuration 41A may include an end fitting member 46
which includes an opening 48 for placement of a device, such as a
pin or shaft. As shown in FIG. 4A, a driving cable 42 having a knot
44 and end fitting member 46 with a circular opening or hole is
shown. The knot 44 and a core tail 47 are located within the end
fitting member 46. The distance L.sub.a from the edge of the end
fitting member 46 to the epicenter of the opening 48 of the end
fitting member 44, and distance L.sub.b from the edge of the end
fitting member 46 to the core tail 47 may be adjusted to meet the
requirements of the desired application.
[0034] Further, as shown in FIG. 4B, another embodiment of the
present invention may include a driving cable 42 and an end fitting
member 46 with an opening 48 suitable for attaching a pin or shaft.
FIG. 4B illustrates an end fitting configuration 40B wherein a core
tail 47 of the driving cable 42 is located within the end fitting
member 46. FIG. 4C further illustrates a cross-sectional view of
the end fitting member 46 as viewed through the opening 48 in the
end fitting member 46.
[0035] The driving cable of the present invention may be used in
the production of a driving system that moves one object into
closer proximity to another object. The objects will have, or
themselves be, points of connection for the driving cable which
traverses the space between the objects. In automotive
applications, the driving cable may serve to open and close
windows, doors, and trunks and a variety of other applications.
[0036] Constructing the plastic driving cable 10 includes providing
an inner core member 16 having end fittings 24, 38, 46 placed at
one or both ends of the plastic driving cable 10. The end fittings
24, 38, 46 can be molded on to the inner core member 16 directly,
or molded separately and attached to the inner core member 16
during an assembly process. An outer jacket 12 may be located in a
position to surround the inner core member 16.
[0037] Several end fitting configurations 21A, 31A, 31B, 41A
include knots 26, 36, 44 which are formed on the inner core member
16 where the end fitting members 24, 38, 46 are located. The knots
26, 36, 44 must be formed after mating components, if used, are
installed, and before the end fitting member 24, 38, 46 being
over-molded on or attached to the inner core member 16 as a
finished cable assembly. Further, the end fitting member 24, 38, 46
may be attached by clamping the end fitting into position on the
plastic driving cable 10.
[0038] The inclusion and type of mating component depends upon the
design and application of the driving cable 10. In a typical
driving system, such as a power sliding door assembly, typical
mating components may include a conduit, pulley, drum, track and
seal. The all-plastic cable often will directly contact each of
these to function within the driving system.
[0039] Driving systems which use all-plastic driving cable may have
several advantages over driving systems currently using metal wire
cables. For instance, the number of components of the system may be
reduced. The inner core of the all-plastic cable is a novel
configuration of intertwined or bundled fibers which can work
together often providing a cable of increased flexibility and
strength. When one specific design was tested, the all-plastic
cable demonstrated a significant increase in flexibility and
strength over some conventional metal cables. In this particular
test, the plastic cable was capable of 200% specification requests
which represents a 40% increase over current metal cables. These
results are merely illustrative of the increased flexibility and
strength of the all-plastic cable, and improvements of this scale
may not be reported in each instance where the metal cable is
replaced with the all-plastic cable. Generally, however, due to the
increased strength and flexibility of the all-plastic cable, it is
usable with the smaller bending radius and therefore often meets
packaging requirements more effectively.
[0040] Although is not necessary, an outer jacket 12 may also be
applied, which is also a novel configuration of non-metallic
materials. When working with a smaller bending radius by replacing
the metal wire with the plastic inner core, the all-plastic cable
can often perform at temperatures as low as -40.degree. C. The
metal cable with an all-plastic outer jacket generally fails at
approximately -30.degree. C. Also, the diameter of the cable may be
enlarged or reduced at a lower cost by adjusting the diameter outer
jacket 12, providing a range of versatile applications at a lower
cost.
[0041] Further, the all-plastic end fittings simplify the design
and processing of the cable. Further, the plastic end fitting
members may be strengthened by reinforcing the plastic resin with
glass fiber, carbon fiber or other materials. Reinforcement of the
end fittings provides strength and resistance, and often reduces
the size of the end fitting while improving performance.
[0042] The lighter weight and high performance of the all-plastic
cable is often an advantage which can simplify the driving systems,
reduce wear and noise and increase performance.
[0043] While the invention has been described in terms of preferred
embodiments, it will be understood, of course, that the invention
is not limited thereto since modifications may be made by those
skilled in the art, particularly in light of foregoing
teachings.
* * * * *