U.S. Pat. No. 8,545,323

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The current game controllers used with the various versions of the Sony PlayStation®, Microsoft Xbox® or other game systems have multiple sets of controls in one small form factor. These controllers are held with two hands and there are typically two different independent systems to control the action for each hand. In one example controller, there is a directional pad and a joystick available for the left hand, and a joystick and joypad (group of buttons) available for the right hand. A user may choose to play with whatever combination of controls he chooses. In addition, the controller is ergonomically shaped so that each hand can wrap around the controller and so that triggers can be pulled with the index finger of each hand. This requires a lobe for the palm of each hand to wrap around and grip. In wireless versions batteries must also be accommodated. Thus, there are space constraints not otherwise present in a stand alone joystick.

In many games, force feedback adds a new dimension to the experience. In particular, driving or other simulation type games that mimic situations with real world gravitational forces that a user is familiar with will enhance the user experience. For instance, gravitational forces acting on a vehicle as it corners or changes velocity can be simulated with the controller by providing resistance to the user's input at the controller. In the case of a joystick, the force feedback can make the joystick easier or more difficult to move in a particular direction based upon the action taking place in the game.

FIG. 1Ashows a prior game controller10that provides force feedback to directional pad12with a pair of electromagnetic drives14A and14B. As can be seen in the figure, the directional pad12and the associated electromagnetic drives14take up a very large portion of the overall controller10. As a rough approximation, directional pad12and the associated electromagnetic drives14occupy the left half of the controller while circuit board16occupies the right half of the controller. Above the circuit board, on the right side, are a group of game control buttons (not shown). Triggers (not shown) are also present on the underside of the controller. Thus, not including the triggers, controller10has two sets of game controls: the directional pad12on the left; and the joypad buttons on the right.

Each electromagnetic drive14(A or B) has two electromagnetic coils18. As can be seen inFIG. 1B, coil18A is on the left and coil18B is on the right. Between the coils is a member that is driven based on the field generated by the coils. The member is coupled to the directional pad12and the force produced at the member by the coils is transmitted to pad12. Position sensor22detects the position of the member. The controller10utilizes a direct coupled electromagnetic drive to provide force feedback to the directional pad. By direct coupled, it is meant that the force produced at the member is coupled to the directional pad without usage of a gear system. While this electromagnetic drive produces relatively fluid feedback free from cogging problems that may be present in a direct drive motor or even a single reduction motor, the electromagnetic drives are large, heavy, and very power hungry. Each axis is controlled by a drive, and each drive requires about 300 mA at 4V. This power requirement renders it impractical for wireless solutions that must depend upon battery power of the controller. The batteries would be consumed in an unacceptably short time with such a system. In fact, with only 500 mA available from a USB connection, this solution is problematic even in a corded controller. In a dual axis force feedback system the 600 mA of current exceeds the 500 mA maximum of the USB standard. Furthermore, the electromagnetic drives are significantly more expensive than the solution provided by the present invention, which will be described with reference toFIGS. 2-8.

FIG. 2illustrates game controller100, an embodiment of the present invention. Controller100comprises a body106. Both controller100and body106are meant to be held with two hands when playing a game and comprise a left lobe10and right lobe112. A player grips each of the lobes and then can manipulate the left set of controls104and the right set of controls,108with a thumb of each hand, and can pull a trigger130(not shown) with another finger such as an index finger. Each set of controls includes two or more different types of controls. The various types include the aforementioned directional pad, game control buttons also referred to as a joypad, and a thumb cap/joystick.

FIG. 3illustrates a main printed circuit board120of the controller. Mounted on a first side, which can be referred to as the top side as it is adjacent the top of the controller, is a mini joystick122. In some preferred embodiments, motor126is mounted on the opposite side of the main circuit board120. On a shaft of motor126is a pinion128. One trigger130is also shown.

FIG. 4is a perspective view, andFIG. 5is an exploded view of assembly102of controller100. Assembly102comprises a printed circuit board, which may be the main printed circuit board120or any other separate or additional printed circuit board. It also comprises motor126, pinion128, double reduction gear132, which itself comprises an intermediate pinion133, annular sector gear134, mini joystick thumb cap136, and joystick gimbal/potentiometer mechanism138. As best seen inFIG. 5, sub frame140has a shaft about which double reduction gear132rotates. Sub frame140also has a shaft about which annular sector gear134pivots. The sub frame extends through the circuit board from the top side of the circuit board to the bottom side, where the motor126mounts to the sub frame. In the particular embodiment illustrated, a cylindrical protrusion surrounding the output shaft fits within a circular hole of the sub frame. This assembly allows the motor to be placed where it can best be accommodated, on the underside of the main circuit board. As mentioned previously, the circuit board need not necessarily be the main circuit board but may be an auxiliary circuit board. In some embodiments, the motor extends into the lobes of the controller. In certain embodiments where a relatively large amount of torque and motor are required in comparison to the body size the body of controller100, the body may include a slight protrusion at the underside to accommodate the motor.

Torque produced by the gear system is multiplied by the combination of the various gears. This enables usage of a relatively small motor in order to produce a desired torque upon thumb cap136. Given that wireless embodiments of controller100with long battery life and play time are important, a smaller and more efficient motor is desirable. Furthermore, the smaller motor, and compact geometry of assembly102in general, allow for a smaller overall controller. As mentioned in the background, prior art controller10is rather large and heavy. This is likely a result of the rather large electromagnetic drive system. Furthermore, on a per axis basis, at 4 volts the prior art force feedback system draws 300 milliamps, whereas at the same voltage the force feedback system of assembly102draws only 50 milliamps. Thus the force feedback system of the present invention consumes about one sixth the power of the prior system: about 0.2 watts vs. 1.2 watts. In embodiments where the force feedback is provided on both the left-right and the front-back axes, this consumption difference is even more important. This is not only the case for wireless embodiments, but also for embodiments drawing power from a USB connection, which is specified to provide a maximum of 2.5 watts.

The ratio of the various gears in combination with the annular sector gear allows for a very compact assembly. Both the compact gear system and the compact motor make possible a smaller and lighter controller. This is an important advantage in a very competitive market where bulky controllers are not commercially successful.

One problem that is present in a direct coupled solution and to a lesser extent in single reduction gearing systems is known as “cogging.” The cogging occurs because the action of the motor produces a somewhat jerky or coarse feeling as the motor turns, which is transmitted to the user and makes the force feedback and the overall controller feel jerky or otherwise poorly actuated. This is, of course, undesirable in a game controller, and the double reduction gear system of the preferred embodiments reduces this to an un-noticeable level in addition to providing a compact and efficient solution for providing force feedback within a game controller.

For further information on the operation and geometry of a double reduction gear system, please refer to U.S. Pat. No. 6,573,885 to McVicar, which is hereby incorporated by reference in its entirety.

FIG. 6illustrates the movement of assembly102along the left-right axis. Intermediate pinion133meshes with the teeth on the concave portion135of annular sector gear134. As the annular sector gear134and thumb cap136pivots, concave portion135travels from one end of the sector to another. A full size gear of the same diameter and/or ratio would be significantly larger and impractical for inclusion in a small controller.

FIG. 7illustrates the movement of assembly102along the front-back axis. As no feedback is provided along this axis the gear system is stationary. Although single axis feedback has been illustrated in the pictured embodiments, other embodiments may include dual axis feedback.

FIG. 8is a cut-away view of controller100. Assembly102is shown actuating one of the controls of the left lobe110of the controller. This feedback may, however, be provided at the left or right side controls. Although in the embodiment shown the motor is directly under the gimbal/potentiometer mechanism138, in other embodiments it extends outside of the footprint towards or into the lobes.

Although the various aspects of the present invention have been described with respect to exemplary embodiments thereof, it will be understood that the present invention is entitled to protection within the full scope of the appended claims.