Patent Application
20090265993
This disclosure relates to a component for automobiles and particularly to a window regulator assembly used to open and close a window in a side door module.
Motor vehicles generally feature side door windows which can be moved between lower (opened) and upper (closed) positions. The mechanism used to move the window between these upper and the lower positions is generally known as a window regulator. A window regulator can either be manually operated by a person or driven by a powered actuator, most commonly an electric motor. One type of window regulator utilizes a pulley system. This pulley system uses a metal cable wrapped around a drum coupled to an electric motor or hand crank to drive a carrier that is fastened to the window and engages a guide rail to control motion as the carrier moves vertically.
Conventional window regulator assemblies may be categorized into either dual rail or single rail configurations. In a dual rail configuration, a pair of separated rails is provided in which each rail includes a clamp fastened to the lower edge of the window. These clamps are then moved in a synchronized manner to raise and lower the window. In a single rail configuration, a single rail is positioned near the center of the window with a clamp fastened at the lower edge of the window. The clamp is then moved vertically along the rail between the open and closed positions. A single rail configuration provides a window regulator assembly with fewer parts than a dual rail configuration. However, the single rail configuration poses a design challenge in providing sufficient stability to control the window's motion. In both the single rail and dual rail configurations, the front and rear edges of the window are retained by and move within a corresponding front and rear window run channel.
Design engineers and manufacturers of automotive components are continuously striving to reduce their cost, complexity, and weight in order to provide features and functions for motor vehicles at minimum cost. In one type of existing single rail configuration, a window clamp is made from stamped sheet metal. This sheet metal part is formed to span across the guide rail in order to adequately engage the rail and to include enough space to mount a pair of separated clamps that fasten to the lower or bottom edge of the window. This large sheet metal stamping is a relatively heavy and expensive component to fabricate.
Therefore, improved regulator assemblies that are relatively light-weight and inexpensive to manufacture are continuously desired. It is also desirable to reduce the complexity of the regulator assembly, thereby, simplifying both the manufacturing and operation of the assembly.
One form of the present disclosure is to provide an improved regulator assembly that can be substantially formed from injection molded plastic resins and to which other components may be added in a manner that provides a cost effective and functional assembly.
A window regulator assembly is described that comprises a window having rear, front, bottom, and top edges; multiple window run channels in which the rear and front window edges reversibly move; a plurality of carrier plates in contact with the bottom edge of the window; a plurality of pulleys, pulley shafts, and pulley attachments; a cable wire; and a drive unit. The pulley attachments may be integrally connected to the window run channel.
In one form of the disclosure, the pulleys and window run channels may be attached to the inner door panel through a threaded shaft and a fastener in order to address exposure to high load forces. The pulleys may be attached to the window run channels via pulley attachments, though the use of a snap-fit fixture, or by welding. The drive unit in the window regulator assembly may be a manually operated hand crank or an automatic actuator, such as an electric motor. The drive unit may be supported by attachment to the door panel.
In the window regulator assembly, a plurality of cable guides may be used to maintain predetermined angles between the cable wire and the pulley and between the cable wire and carrier plate. These cable guides may be integrally formed with the window run channels or snapped in place. Due to possible obstruction with other components in the door module, the cable may also be routed through a conduit.
The present disclosure provides a means through which the weight and cost of the window regulator assembly may be reduced. Various components of the window regulator system, such as the window run channels, carrier plates, pulleys, pulley shafts, and pulley attachments, as well as any gears in the drive unit may be formed from a thermoplastic material. The thermoplastic material may be formed into the component through injection molding, thermoforming, extrusion, or any other means known to one skilled-in-the-art. When desirable these same components may be formed from metal and welded or attached within the door module.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and any specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is in no way intended to limit the present disclosure or its application or uses. It should be understood that throughout the description and drawings, corresponding reference numerals indicate like or corresponding parts and features.
In
The window 5 may be formed from glass, a thermoplastic resin, or any other substantially transparent glazing material known to someone skilled-in-the-art. Examples of thermoplastic resins suitable for use as a window 5 include, but are not limited to, polycarbonate, acrylic resins, polyarylate resins, polyester resins, and polysulfone resins.
Now with reference to
The front 7 and rear 4 window run channels are preferably formed from a thermoplastic material in order to reduce weight and to simplify integration with and provide support for other components in the window regulator assembly. Examples of thermoplastic materials suitable for use as a window run channel include, but are not limited to, polyamides, polyalkyene terephthalates, polycarbonates, polyurethanes, acrylonitrile butadiene styrene (ABS), polyesters, nylon, polyoxymethylene (POM), nylon, polypropylene, and mixtures or blends thereof. For strength and reinforcement the thermoplastic materials may incorporate fillers, such as but not limited to long glass fibers (LGF), glass particles, carbon black, and silica. One skilled-in-the-art will recognize that other materials including conventional metal may be used to form the window run channels. The run channels may be attached, fastened, or welded to the outer door panel 20.
The carrier plate 10 shown in
As shown in
Continuing with
Due to an obstruction from another component in the door module 1, it may be desirable in certain instances to alter the routing of the cable wire 15 through the use of a conduit 16. Such conduit 16 may be any flexible non-metallic or metallic sheath known to one skilled-in-the-art. The sheath may be further reinforced with a wound plastic spiral spring, metal wire, or any other type of reinforcement. A conduit can be used in conjunction with the cable wire 15 and any pulley 3 as deemed desirable. For example, in
The window regulator assembly 2 may also utilize a cable guide 12 to protect the cable wire 15 along the length of the window run channels 4 & 7. Cable guides 12 may be integrally formed with the window run channels 4 & 7 or be a separate assembly. The purpose of the cable guide 12 is to maintain predetermined angles between the cable wire 15 and the pulleys 3, as well as between the cable wire 15 and the carrier plates 10. The window regulator assembly 2 may include a plurality of cable guides 12. A cable guide 12 may make contact with the window run channels 4 & 7 through a snap-on fastener or clip.
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In
The pulleys 3 and their corresponding pulley shafts 21, as well as pulley attachments 9, cable guides 12, carrier plates 10 and other components, including but not limited to, the gears in the drive unit 17, may be formed from a thermoplastic material or a metal. Examples of thermoplastic materials suitable for use include, but are not limited to, polyamides, polyalkyene terephthalates, polycarbonates, polyurethanes, acrylonitrile butadiene styrene (ABS), polyesters, nylon, polyoxymethylene (POM), nylon, polypropylene, and mixtures or blends thereof. For strength and reinforcement the thermoplastic materials may incorporate fillers, such as but limited to long glass fibers (LGF), glass particles, carbon black, and silica. One skilled-in-the-art will recognize that other materials may also be used, such as conventional metals.
Thermoplastic materials may be formed into the components described above using any technique known to one skilled-in-the-art. Examples of suitable techniques include, but are not limited to, injection molding, thermoforming, and extrusion. Metals may be formed into the components described above, as well as the window run channels, using any technique known to one skilled-in-the-art, including but not limited to, roll forming, forging, extrusion & drawing, sheet metal forming, and powder metallurgy.
A person skilled in the art will recognize from the previous description that modifications and changes can be made to the present disclosure without departing from the scope of the disclosure as defined in the following claims.
