Sliding door system for vehicles

[0002] This invention generally relates to a sliding door for a vehicle and, more particularly, to a connection that allows for an uninterrupted transfer of electrical power and signals between a vehicle body and the sliding door.

[0003] While the background of this invention as discussed below is in the context of power sliding doors for vehicles, those of ordinary skill in the art will appreciate that the present invention has application well beyond that. Specifically, this invention would alleviate many of the problems commonly associated with electrically connecting a first member that slidably moves in a non-linear manner relative to a second member.

[0004] The imnmense popularity of vans, mini-vans and sport utility vehicles among consumers is readily apparent. The reasons are clear. Aside from the relative safety of larger vehicles when compared to small, they also allow for the comfortable transportation of families, including those with small children.

[0005] Common to both vans and mini-vans is the use of a rear sliding door rather than a pivoting door to access the rear cabin. Sliding doors are generally mounted on two or more guide tracks that are attached to a vehicle body for slidably moving between a closed, a released, and a fuill-open position. Sliding doors can thus provide a much larger area for the ingress and egress of passengers and other cargo from the rear cabin.

[0006] Sliding doors do present design challenges, however. For example, sliding doors are often heavier than their pivoting door counterparts. In addition, a sliding door's center of gravity will move rearward relative to the sliding door's support arrangement as the sliding door moves to a full-open position. As a result, moving a sliding door from a closed position outward and rearward to a released position, and then to a ftill-open position requires more strength than children, senior citizens and persons who are physically limited can muster. The same difficulties obtain when attempting to move the sliding door from a full-open position back to a closed position. Of course, when the vehicle is on hilly or uneven tenrain, the problems associated with opening and closing the sliding door will be magnified.

[0007] In light of the above, and in recognition of increasing consumer demand for greater convenience, power sliding doors for vehicles have been introduced into the marketplace. For example, in U.S. Pat. No. 5,046,283 to Compeau el al. the use of a motorized mechanism for moving a sliding door is disclosed. Specifically, Compeau et al. teaches using a drive mechanism mounted to the vehicle body to wind and unwind cables that are fixedly attached to the sliding door. Thus, when the mechanism drives in a first direction, the sliding door opens, and, when the mechanism drives in a second direction, the sliding door closes.

[0008] This invention, on the other hand, is directed to a system that uses a wire track assembly capable of providing continuous electrical power between the sliding door and vehicle body as opposed to merely linking a sliding door and vehicle body through mechanical means. Specifically, the wire track assembly can provide direct and uninterrupted electrical communication both to and from the sliding door and the vehicle body. As a result, electrical devices such as motors and sensors can be mounted on or in the sliding door.

[0009] The advantages of continuous electrical communication between the sliding door and vehicle body are apparent to those of ordinary skill in the art. For example, safety sensors may flow be placed on the vehicle sliding door at optimum sensing locations so that the sliding door's forward or rearward movement relative to the vehicle body may be stopped at any time during its travel between the full-open and closed positions, and back again. Or, rather than attaching a motorized driving mechanism for the sliding door to the vehicle body, the mechanism may instead be mounted directly on or in the sliding door.

[0010] Providing a continuous electrical link between a sliding door and a vehicle body also presents design challenges. In this regard, a vehicle sliding door generally has a first hinge and a second hinge, with the first hinge and the second hinge affixed to the lower forward corner and upper forward corner of the sliding door, respectively. Attached to the first and second hinges are guide rollers adapted for cooperation with a first guide track and a second guide track. The first and second guide tracks are in turn attached to the vehicle's body. The guide tracks commonly extend horizontally along the vehicle body, above and below the vehicle body's door opening.

[0011] When in a closed position, the vehicle sliding door sits in a generally flush position relative to the vehicle body. Consequently, when opening the sliding door, the sliding door's rear edge must first pivot outward and rearward relative to the vehicle body to a released position. Only then can the sliding door move in a generally horizontal direction on the guide tracks to its full-open position. Accordingly, the guide tracks are non-linear.

[0012] In other words, the vehicle sliding door must move through an arcuate path along the guide tracks from (1) a closed position where the sliding door is flush with a vehicle body; (2) to a released position where the rear edge of the sliding door relative to the vehicle body moves outward and rearward; (3) to a full-open position; and (4) back again. Of course, the integrity of the electrical connection between the sliding door and vehicle body has to be maintained notwithstanding the non-linear movement of the sliding door. This is the case even after a large number of duty cycles.

[0013] Accordingly, one object of this invention is to provide a new and improved sliding door system for vehicles wherein the sliding door and vehicle may be in continuous electrical communication with each other. Still another object of this invention is to provide a wire track assembly that operates in a reliable and efficient manncr to permit uninterrupted electrical communication between the sliding door and vehicle notwithstanding the non-linear path of the sliding door relative to the vehicle body even after a large number of duty cycles.

[0014] These and other features and advantages of the invention will be more fully understood from the following detailed description of the invention taken together with the accompanying drawings.

[0015] FIG. 1 is a perspective view of a vehicle with a sliding door system in accordance with the present invention with the sliding door shown in a closed position;

[0016] FIG. 2 is a partial view of a door opening of the same embodiment of the power sliding door system shown in FIG. 1 with the sliding door shown in a full-open position showing a wire track assembly;

[0017] FIG. 3 is a top view of the door opening of the same embodiment of a powered sliding door system shown in FIG. 1 and FIG. 2;

[0018] FIG. 4 is a cross-sectional view of the door opening shown in FIG. 3, the section being taken along line 4—4 of FIG. 3;

[0019] FIG. 5 is a perspective view of a main body link of the wire track assembly in accordance with the present invention;

[0020] FIG. 6 is an elevational view of the main body link shown in FIG. 5;

[0021] FIG. 7 is an elevational view of a pair of main body links fittingly engaged;

[0022] FIG. 8 is an elevational view of a fixed end link of the wire track assembly in accordance with the present invention;

[0023] FIG. 9 is an elevational view of a driven end link of the wire track assembly in accordance with the present invention; and

[0024] FIG. 10 is a perspective, partial sectional view of the inside of the sliding door in one embodiment of the present invention.

[0025] One embodiment of the power sliding door system for vehicles according to this invention is shown in FIG. 1. A vehicle 10 has a vehicle body 12. The vehicle body 12 has an opening 14 defined by a first horizontal channel 16 and a second horizontal channel 18, and by a first body pillar 20 and a second body pillar 22. The opening 14 in vehicle body 12 is adapted for receiving a sliding door 24, with the sliding door 24 being slidably mounted on a first guide track 26 and a second guide track 28. As can be seen in FIG. 3, the first guLide track 26 is adjacent the first channel 16 of vehicle body 12 in this embodiment.

[0026] As is best shown in FIG. 10, the sliding door 24 has a first hinge 30 and a second hinge 34, with the first hinge 30 fixedly attached to the lower forward corner of the sliding door 24 relative to the front of the vehicle 10, and the second hinge 34 fixedly attached to the upper forward corner of the sliding door 24 relative to the front of the vehicle 10. Attached to the first hinge 30 and the second hinge 34 are a first guide roller 32 and a second guide roller 36, respectively. The first guide roller 32 is adapted for cooperation with the first puide track 26, and the second guide roller 36 is adapted for cooperation with the second guide track 28. Referring to FIG. 2 and FIG. 3, the first guide track 26 curves inward relative to the vehicle's 10 interior as it approaches first body pillar 20. This perits the sliding door 24 to sit in a generally flush position to the vehicle body 12 when the sliding door 24 is in a closed position as shown in FIG. 1.

[0027] As is best shown in FIG. 2 and FIG. 3, adjacent the first guide track 26 in the first channel 16 is a sill 38. The sill 38 is defined by a surface 40 between a first sidewall 42 and a second sidewall 44. The first sidewall 42 and the second sderwall 44 of the sill 38 generally follows the first guide track's 26 curved path. The sill 38 may therefore assist in guidiet a wire track assembly 46 when the slidinig door 24 moves from a closed, to a released, to a full-open position, and then back again.

[0028] Because the sill 38 in this embodiment may be exposed to elements like dust, dirt and water, the sill 38 has a plurality of formnations 48 oriented in a generally perpenidicular manner relative to the second sidewall 44. The formations 48 serve to minimize points of contact between the wire track assembly 46 and the surface 40 of the sill 38. The formations 48 thus reduce friction between the wire track assembly 46 and the surface 40, and also reduce the exposure of the wire track assembly 46 to undesirable conditions.

[0029] As shown in FIG. 4, the wire track assembly 46 between the vehicle body 12 and the sliding door 24 in this embodiment comprises a plurality of electrical wires 50 that are enclosed in a sheathing 52. The sheathing 52 is comprised of numerous main body links. One skilled in the art will appreciate that the number of main body links will vary in accordance with such variables as the desired length of the wirc track assembly 46.

[0030] A main body link 54 is shown in FIG. 5 and FIG. 6. As can be seen, a main body link 54 has a first round retaining wall 56 and a second round retaining wall 58 at a first end. In addition, the main body link 54 has a first elliptical aperture 60 and a second elliptical aperture 62 at a second end. As demonstrated in FIG. 7, the diameter of an elliptical aperture 64 of a main body link 66 are such that the elliptical aperture 64 of main body link 66 may fittingly engage a second main body link's 68 round retaining wall 70. In this embodiment, the shape and diameter of the elliptical aperture 64 of main body link 68 in relation to the second main body link's 68 round retaining wall 70 permits the sheathing 52 to bend transversely relative to the longitudinal axis of the wire track assembly 46. The transverse flexibility of the sheathing 52 when comprised of a plurality of main body links 54 helps the wire track assembly 46 negotiate the non-linear movement of the wire track assembly 46 as required by the non-linear movement of the sliding door 24.

[0031] At a first end of the wire track assembly 46 is a fixed end link 72 that is attached to the vehicle body 12 at sill 38. As shown in FIG. 8, the fixed end link 72 has a clip-slidc feature 74 adapted for receiving a fastener. In this embodiment, a double Christmas-Tree push fastener 76 is attached to the fixed end link 72 via the clip-slide feature 74. The fixed end link 72 may be fastened to the vehicle body 12 through holes located near the horizontal midpoint of surface 40 and the sill 38. Those of ordinary skill in the art will appreciate that there are numerous alternatives for fastening the wire track assembly 46 to the vehicle body 12. The method presented in this embodiment, however, positively mounts the fixed end link 72 to the vehicle body 12, and assists in maintaining the wire track assembly's 46 longitudinal orientation.

[0032] As indicated in FIG. 9 and FIG. 10, the wire track assembly 46 also has a driven end link 78 at a second end 80 that is attached to the first hinge 30 of the sliding door 24. The first hinge 30 has an slot 82 adapted for receiving an attachment stud 84. The driven end link 78 has a socket 86 having a first bore 88 and a second bore 90, also adapted for receiving the attachment stud 84. The attachment stud 84 has a shoulder 92 adapted to sit upon a first side 94 of the socket 86 that defines the first bore 88 of the driven end link 78. Thus, in attaching the wire track assembly 46 to the first hinge 30, the attachment stud 84 is driven through the slot 82 on the first hinge 30, as well as the first bore 88 and the second bore 90 of driven end link 78. The attachment stud 84 is then locked into place with a clip lock 96, adapted to fixedly engage the driven end link 78 and the attachment stud 84. Again, those of ordinary skill in the art will appreciate the variety of ways in which the wire track assembly 46 may be attached to the first hinge 30 of the sliding door 24. One of the advantages to this embodiment is that the attachment stud 84 allows for rotational movement of the driven end link 78 around the first hinge 30, thereby aiding in reducing torsion stress on the wire track assembly 46.

[0033] Finally, the advantages of electrical communication between the vehicle body 12 and the sliding door 24 in this embodiment are shown in FIG. 10. Wire track assembly 46, which houses electrical wires 50 is attached to the first hinge 30 of the sliding door 24. Attachment of the wire track assembly 46 to the first hinge 30 is effected via the driven end link 78, attachment stud 84, opening 82 in first hinge 30, and clip lock 96. Electrical wires 50 may be capable of providing uninterrupted electrical power and signals to and from the sliding door 24.

[0034] As a result, such things as a drive motor 98 can be mounted within the sliding door 24 to engage a power drive gear 100 through a drive cable 102. The power drive gear 100 is housed in a module 104 attached to the first hinge 30. When activated, the power drive gear 100 engages a rack 106 best shown in FIG. 4 and FIG. 5, thereby slidably moving the sliding door 24 relative to the vehicle body 12 through a plurality of positions. Alternatively, the drive motor 98, drive gear 100, and drive cable 102 may be removed providing a manual sliding door. In addition, an object detector 108 can be attached to an edge 110 of the sliding door 24.

[0035] While the above detailed description describes the preferred embodiment of the present invention, it will be understood that the present invention is susceptible to modification, variation and alteration without deviating from the scope and fair meaning of the subjoined claims.