Panel assembly for vehicles with molded regulator attachment

A panel/window assembly for vehicles adapted to be raised and lowered by a window regulator mechanism. The assembly includes at least one regulator mechanism attachment member molded directly on one peripheral edge of a preferably transparent sheet from a resinous material, preferably reaction injection molded polyurethane. The attachment member may include either a generally C-shaped channel having an elongated slot opening to one side or an elongated opening extending entirely through the attachment member. The opening or channel in each attachment member is adapted to receive a roller or slide mechanism coupled to the regulator mechanism. Preferably, the slide is coupled to the regulator arm by a cap received over the end of the arm and includes a pivot joint allowing movement about multiple axes. The panel/window assembly allows installation on existing or new regulator assemblies and requires less time and fewer tools to install than conventional window assemblies.

FIELD OF THE INVENTION 
This invention relates to panel assemblies especially adapted for use as 
windows in vehicles or other structures where the window must be raised or 
lowered usually by sliding movement by means of a window regulator 
mechanism connected to the window assembly. More particularly, the 
invention is a window panel assembly providing one or more attachment 
members which are molded directly in place on a sheet of material for 
receiving a roller or glide assembly and coupled to a window regulator 
mechanism. 
BACKGROUND OF THE INVENTION 
In a typical vehicle, two or more side window panels are provided adjacent 
the driver and passenger which may be raised and lowered usually by 
sliding movement via hand operated or electrical mechanisms. The window 
panel assemblies are mounted in tracks or channels and are generally moved 
vertically. It is common to provide a metal bracket along the bottom edge 
of the window which allows for the attachment of a scissor-like linkage, 
gear driven regulator mechanism, tape or cable drive system all of which 
are generally known as window regulator mechanisms to move the window when 
desired. The prior known brackets have normally been rigidly attached to 
the sheet glass forming the window in various ways to provide a channel 
for receipt of rollers or other connections to the mechanisms. 
Various drawbacks have been encountered in prior known window panel 
assemblies incorporating such brackets. First, metal brackets are 
expensive to manufacture and/or expensive to attach to the glass window 
panel without breakage. Generally, the metal brackets required additional 
labor and/or processing steps. In some cases, the metal brackets loosened 
after attachment or after installation in the vehicle causing malfunction 
of the window regulator mechanism and trapping the window either in an 
open or partially open position. 
Secondly, the prior known metal brackets are difficult to consistently 
manufacture in closely fitted tolerances. Hence, the fit of the window 
regulator roller or other mechanism portion to the brackets varied within 
wide ranges. In some cases, the tolerance was sufficiently large to cause 
vibration or rattles between the regulator mechanism connection and the 
sheet creating annoyance and inconvenience to the vehicle owner. 
Thirdly, the prior known metal brackets were often difficult to adapt to 
the position requirements of the window regulator rollers and other 
mechanism portions. The brackets often required sharp bends in the metal 
to locate the channel or other bracket portions appropriately for 
connection to the roller mechanisms. In addition, it was often necessary 
to preassemble portions of the regulator mechanism followed by further 
assembly steps after insertion in the bracket to enclose the rollers 
properly in position. Alternately, many roller assemblies had to be 
completely assembled within the metal brackets for proper installation. 
All of the above problems added to the inconvenience and expense of 
providing proper mounting for window regulator mechanisms on sheet glass 
and other windows and panels in vehicles. The present invention was 
devised as a solution for these and other problems by providing a panel 
assembly including an attachment member molded directly on the glass or 
other sheet material of the sheet thereby eliminating the need for 
separate metal brackets and the above attendant problems. Moreover, the 
present invention provides a means for coupling the molded attachment 
member to existing window regulator mechanisms without significant 
modification. 
SUMMARY OF THE INVENTION 
Accordingly, the present invention provides a panel assembly especially 
adapted for use in vehicle windows including an attachment member molded 
directly on the sheet material of the assembly from a resinous material 
without requiring any fastening members to extend through the sheet. The 
panel is adapted for raising and lowering, typically by sliding movement, 
via one of several types of regulator mechanisms such as a scissor 
linkage, or the like, which may be conveniently assembled to the 
attachment member. 
In one form, the invention is a panel assembly comprising a sheet of 
material, such as glass or the like, and at least one attachment member 
for connecting the sheet to a support such as a window regulator 
mechanism. The attachment member is molded directly on the peripheral edge 
of the sheet from a moldable, resinous material such that the member is 
securely adhered to the sheet during molding. The attachment member has 
securing flanges extending along both side surfaces of the sheet which 
encapsulate the peripheral sheet edge and an elongated slot extending 
along the length of the member for receiving a roller or glide assembly 
coupled to the window regulator mechanism. Access means are included for 
inserting the roller or glide assembly in the slot. The assembly allows a 
portion of the regulator mechanism to be supported on the attachment 
member for movement in the slot to move the panel assembly between desired 
positions. 
In a preferred form of the invention, the attachment member may include an 
elongated, generally C-shaped channel portion with the slot comprising an 
elongated opening in one side of the channel. The opening communicates to 
the channel portion interior for receiving a roller or glide assembly 
coupled to the window regulator mechanism. In one form, the channel 
portion overlaps the peripheral sheet edge. Alternately, the C-shaped 
channel portion may be aligned with the peripheral edge of the sheet. 
In another form of the invention, the attachment member may include an 
attachment flange extending outwardly of the peripheral sheet edge and a 
slot comprising an elongated opening having closed ends and extending 
entirely through the attachment flange enabling access thereto from either 
side of the assembly. Such opening is adapted to receive the roller or 
glide assembly attached to the window regulator mechanism. At least one of 
the closed ends of the elongated opening preferably includes an enlarged 
area adapted to receive the roller or glide assembly from the regulator 
mechanism prior to insertion into the elongated opening. In addition, 
depending on the length of the attachment member, a molded support may be 
included across the opening for additional strength. Moreover, the 
attachment member may be made rigid by the addition of a stiffener encased 
within the lower edge. 
In either form of the invention, molded securing flanges extend toward the 
center of the sheet on the attachment member, at least one of which may 
include an area of increased thickness as compared to the remainder of 
either securing flange to enhance adherence of the molded attachment 
member to the sheet glass. In addition, with either form of the attachment 
member, a spaced pair of attachment members may be formed on one edge, 
typically the lower edge, of the panel in order to reduce material 
requirements based on the known paths of travel of the regulator 
mechanisms. 
In yet other aspects of the invention, the attachment member or members may 
be molded integrally with gasket portions on other sheet edge portions of 
the assembly to provide guides for raising and lowering the window. 
Preferably, the attachment members are formed on the sheet by molding with 
a resinous, polymeric molding material such as reaction injection molded 
polyurethane, the attachment members being adhered and bonded to the sheet 
by forming and curing within a mold apparatus. 
In accordance with yet another form of the invention, the attachment 
members having an elongated slot extending entirely therethrough may be 
coupled to new or existing window regulator mechanisms by a glide means. 
The glide means includes a slide having a generally rectangular body 
containing an upper and a lower channel to receive the upper and lower 
surfaces of the slot in the attachment member. In a preferred embodiment, 
the slide body is pivotally coupled to an arm of the window regulator 
mechanism. The coupling provides a universal joint between the window and 
the window regulator mechanism. In another embodiment, the slide body is 
rigidly coupled to the arm of the window regulator mechanism. The upper 
and lower channels of the rigidly-fixed slide have convex floors and 
outwardly inclined walls so as to pivot about its longitudinal axis while 
in the elongated slot of the attachment member. 
In still another embodiment of the invention, wherein the attachment member 
includes an elongated, generally C-shaped channel portion, the glide means 
coupling the attachment member to the window regulator mechanism includes 
a generally rectangular slide. The cross-sectional profile of the slide is 
substantially similar to that of the C-shaped channel and adapted to slide 
therein to move the window between the desired positions. The slide may be 
fastened to the arm of the window regulator mechanism by a suitable 
coupler such as that described above. 
As will be understood from the invention, numerous advantages over prior 
known panel/window assemblies are provided by this invention. These 
include cost savings and manufacturing simplification by the elimination 
of prior known metal brackets due to the complete formation of necessary 
window regulator attachment members by molding. The molded attachment 
members provide significantly better manufacturing consistency and 
tolerance for fitting with rollers and other portions of the regulator 
mechanisms. The closer tolerance provided by the molded attachment members 
eliminates vibration and rattles encountered in prior known assemblies, 
the molded attachment members also enable easier attachment and 
installation of the regulator mechanisms, and provide a greater ability to 
properly position the attachment members for connection to the regulator 
mechanism in the vehicle itself. Further, the molded attachment members 
eliminate the need for multiple, preformed, separate elements which must 
be joined together. Moreover, the molded attachment members are durable 
and non-corrosive and well adapted for use in the often harsh environments 
encountered during vehicular use in varying climates. Yet another 
advantage of the instant invention is the ability to place the window 
panel assembly in existing vehicles using the new coupler for attaching 
the window panel to existing window regulator mechanisms. 
The glide assemblies used with the attachment members and panel assemblies 
may be used with existing or new window regulator mechanisms. In 
particular, the glide assemblies provide a pivotal coupling with limited 
freedom and may be used with curved windows or panel assemblies which must 
rotate or move with respect to the window regulator mechanism as they are 
moved from the open to the closed position. The glide assemblies may also 
be used with windows or panel assemblies which move out and become flush 
with the vehicle body. The glide assemblies may be inserted into the 
attachment members before the pane or window assembly is inserted in the 
vehicle door enabling easier attachment and installation of the regulator 
mechanisms, and a greater ability to properly position the attachment 
members for connection to the window regulator mechanism. The glide 
assembly may be preassembled with the panel and shipped as a single unit, 
reducing the need to assemble many separate parts. The slide is durable 
and inexpensive and easy to manufacture. 
These and other objects, advantages, purposes and features of the invention 
will become more apparent from a study of the following description taken 
in conjunction with the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring now to the drawings in greater detail, FIGS. 1 and 2 illustrate a 
first embodiment 10 of the window panel assembly of the present invention. 
Assembly 10 is specifically adapted for use as a vehicle window and 
includes a configured, preferably curved sheet 12 of transparent glass 
which may be tempered, laminated or otherwise strengthened with 
conventional principles and also includes two spaced attachment members 
14, 16 and a pair of spaced, peripheral edge gasket or casing portions 18, 
20. Preferably, attachment members 14, 16 and gasket or casing portions 
18, 20 are all simultaneously formed directly on the sheet glass 12 in a 
molding apparatus into which sheet 12 is inserted from a resinous plastic 
or polymeric molding material, preferably reaction injection molded 
polyurethane, or polyvinyl chloride, of sufficient strength, rigidity and 
hardness to withstand operation of the window and regulator mechanism. 
Attachment members 14, 16 are adapted to receive therein the rollers from 
a scissor-type window regulator or raising and lowering mechanism M shown 
in phantom in FIG. 1. Spaced gasket portions 18, 20 may also be formed on 
other peripheral edge portions such as the vertical rear edge of the 
window and the vertical forward edge of the window. Rear and front edge 
gasket portions 18, 20 are adapted to be received in tracks or channels T 
shown in phantom in FIG. 1, which tracks are usually fitted in the doors 
of a vehicle to guide the substantially vertical movement of the window 
assembly. 
With reference to FIGS. 2 and 3, the lower half of a suitable mold 
apparatus A is shown in phantom including representative runners or 
channels 22, 24, 26 through which mold materials such as polymeric 
reaction injection molded (RIM) polyurethane components, which have been 
previously mixed together with an aftermixer device, or polyvinyl chloride 
materials, are injected into suitable mold cavities to form attachment 
members 14, 16, as well as gasket or casing portions 18, 20, on the 
transparent sheet 12 which is simultaneously held within the mold half. 
The channels or runners include a main runner 22 leading to a bifurcated 
channel 24, 26 having fan-shaped exit portions 24a, 26a adapted to 
introduce molding material into a first cavity which forms gasket portion 
18 and connecting portion 18a, as well as a second cavity for gasket 
portion 20 and connecting portion 20a. Connecting portions 18a, 20a extend 
from opposite ends of attachment members 14, 16. The cavity which forms 
attachment member 14 acts as a connection chamber leading to the smaller 
cavity forming connection portion 18a which is adhered to the lower edge 
of sheet 12 and which, in turn, leads to the cavity forming gasket portion 
18. Likewise, the cavity which forms attachment member 16 acts as a 
connection chamber leading to the smaller cavity forming connection 
portion 20a which extends along another portion of the lower edge of sheet 
12 and, in turn, leads to the cavity forming gasket portion 20. In the 
preferred embodiment, attachment members 14, 16 are not joined by any 
molded portion or the like. However, a variant of the window assembly 
could be formed by using either runner 24 or 26 alone and having a 
connection portion intermediate the attachment members 14, 16 such that 
only a single exit portion or runner could be used to fill the entire 
cavity along the entire length of the sheet edge to be encapsulated. 
Prior to injecting polymeric material through runners 22, 24 and 26, a 
sheet 12 of transparent material, preferably glass, is placed within the 
recess in mold half A such that the edges of the sheet project into the 
mold cavities adapted to form the attachment members 14, 16, connecting 
portions 18a, 20a, and gaskets 18 and 20. Prior to such insertion, sheet 
12 is preferably coated on the edges which will receive the attachment 
members, connecting portions and gaskets with a suitable conventionally 
known primer coating which enhances the adherence or bond between the 
polymeric material and the glass surfaces during molding. Thereafter, the 
desired polymeric material is injected through the runners or channels 22, 
24 and 26 such that the mold cavities are filled. As will be understood 
from FIG. 4, attachment members 14, 16 include a section which envelopes 
and encapsulates the edge of glass sheet 12. After the polymeric material 
cures and/or sets up within the mold, the formed window panel assembly, 
including attachment members 14, 16, connecting portions 18a, 20a, and 
gasket portions 18, 20, is removed from the mold once the top half of the 
mold apparatus is withdrawn. As is conventionally known in the molding 
art, appropriate seals may be included in the upper and lower mold halves 
to close off cavities forming these molded portions within the mold to 
prevent the escape of molding material onto the center portions of glass 
sheet 12 and from the mold apparatus overall during the molding process. 
Although the use of plastic or polymeric molding materials such as reaction 
injected molded (RIM) polyurethane is preferred, polyvinyl chloride could 
alternately be used for the attachment members, connecting portions and 
gasket members if made sufficiently rigid to support the window regulator 
mechanism rollers and such that gasket portions 18, 20 which slide in 
guide tracks T are also sufficiently rigid. A suitable primer to be 
applied to glass sheet 12 before molding of these portions from the 
reaction injection molded polyurethane may be obtained from Lord 
Corporation of Erie, Pa., under the product designation Chemlook AP-134. 
In addition, it is possible that other polymeric and/or moldable materials 
may be used to form these molded portions and that other transparent 
sheetings such as acrylic or other plastic materials may be used instead 
of glass depending on the desired window application. Of course, glass 
coated with an opaque or translucent frit layer or other opaque or 
translucent sheet materials may be substituted for the transparent glass 
or plastic sheeting of assembly 10 to produce other panel assemblies 
within the scope of this invention. 
Referring now to FIGS. 1, 2 and 4, each of the spaced attachment members 
14, 16 includes a generally C-shaped channel portion 28 and securing 
flanges 30, 32 which envelope and encapsulate the edge and adjacent 
periphery of glass sheet 12 at the location of the attaching member. 
Molded securing flanges 30, 32 extend inwardly toward the center of sheet 
12 along the sheet side surfaces from the peripheral edge. Securing flange 
30 forms one sidewall of the channel portion 28 which overlaps the 
peripheral edge of sheet 12, as shown in FIG. 4. Channel portion 28 also 
includes a top wall 34, bottom wall 36 and retaining flanges 38, 40 which 
define an elongated interior channel 43. Flanges 38, 40 are in alignment 
and extend toward one another to define an elongated, side opening 42 
which is opposed to the closed side of channel portion 43 formed by 
securing flange 30. Bottom wall 36 merges into the lower portion of 
securing flange 32 thereby enclosing the peripheral edge of the sheet. 
Along one portion of securing flange 32 adjacent the periphery of the 
sheet is formed in elongated area 44 having an increased thickness as 
compared to the remainder of the securing flange 32 or the other securing 
flange 30. Increased thickness area 44 provides enhanced adherence of the 
molded material to glass sheet 12 by providing a higher curing heat for 
the primer thereby producing better overall adhesion strength for the mold 
material to the glass after molding. 
As is best seen in FIG. 4, elongated channel 43 is also elongated in the 
height dimension. The ends of channel portion 43 are open for access to 
and insertion of a suitable roller from the window regulator mechanism M, 
as shown in FIG. 4. Although confining members may be inserted in the ends 
of the channel after insertion of the roller therethrough, they are not 
typically needed because the entire assembly 10 is confined in tracks T in 
the vehicle and mechanism M prevents removal of the rollers. The molded 
RIM polyurethane material is of sufficient strength to support roller R on 
bottom wall 36 without deflection in order to raise and lower window 
assembly 10 in a sliding movement along tracks T, as shown in FIG. 1. 
Approximately one-half of the height of channel 43 lies inside or toward 
the center of sheet 12 from its peripheral edge. The remaining half 
projects outwardly of the peripheral edge thereby providing the 
overlapping position of the channel with respect to the edge. Such 
position helps provide additional support for channel portion 28 by means 
of rigid sheet glass 12 acting as a backup support for the channel. As is 
also apparent from FIGS. 1, 2 and 4, channel portion 43 in each of the 
attaching members is generally rectilinear as is the lower edge of sheet 
12 in the preferred embodiment. Preferably, attaching members 14, 16 are 
molded on sheet 12 such that opening 42 and channels 43 extend generally 
parallel to the lower edge, as shown in FIG. 2. It is within the scope of 
the present invention, however, to provide other than rectilinear channels 
depending on the motion to be provided for assembly 10. In this respect, 
molding a curved channel in each of the attaching members may cause the 
window assembly to tip or rotate in a fore and aft direction as it is 
being raised or lowered, or be moved at other than a constant rate within 
different portions of the tracks T. The molding process for attachment 
members 14, 16 is uniquely adapted to provide different configurations 
while maintaining the close tolerance necessary for precision fitting of 
window regulator mechanism to the window assemblies. 
As shown in FIG. 2, when rollers R from opposite portions of scissor-type 
window regulator mechanism M (FIG. 1) are received in channels 43 of 
spaced attachment member 14, 16, the bar members upon which rollers R are 
mounted may be pivoted by an appropriate manual or power mechanism about 
the center pivot to raise or lower window assembly 10. Based on the 
connection point and positioning of the regulator mechanism, the rollers 
will travel different distances along channel portions 43 during such 
motion. The limits of travel for the rollers in a typical scissor-type 
window regulator mechanism M are shown in phantom in FIG. 2. As is 
apparent, neither roller approaches the extreme end of attachment member 
14, 16. In addition, the area between attachment members 14, 16 is not 
required as a track or channel portion for receipt of the rollers during 
normal motion. Hence, by eliminating the center section between members 
14, 16, material is saved and the overall cost of the assembly is lowered. 
Alternately, however, a single continuous attachment member 14A may be used 
in the assembly as is shown in FIG. 3 where like numerals indicate like 
parts to those in attachment members 14, 16. In member 14A, which has the 
same shape in section as members 14, 16, the same top, bottom and 
sidewalls are provided adjacent the periphery of sheet 12 but in a longer, 
more extended length. Likewise, securing flanges 30, 32 are included along 
with increased thickness area 44 to provide enhanced adherence. In this 
form, only a single channel or runner 24 or 26 is required to fill the 
cavity in the mold forming member 14A, which cavity in turn leads to the 
connecting portions 18A, 20A and to gaskets 18, 20, respectively. As with 
each of the attaching members 14, 16, the ends of channel portion 43 are 
open allowing insertion of rollers R. As above, channel 43 overlaps the 
peripheral edge of sheet 12. The center section of attaching member A (not 
present in assembly 10 which uses separate attaching members 14, 16) also 
helps to increase the adhering strength of the channel portion to the 
glass to ensure retention of the window regulator mechanism to the window 
glass throughout the life of the vehicle in which it is installed. 
With reference to FIGS. 5 and 6, a third embodiment 50 of the window panel 
assembly is shown including a single, elongated attachment member 52 
molded directly on the lower edge of a sheet 12 of transparent glass as in 
embodiments 10 and 14A. In embodiment 50, attaching member 52 includes a 
channel portion 54 and a pair of securing flanges 56, 58 which envelope 
and encapsulate the periphery and edge of a lower portion of sheet 12, as 
shown in FIG. 6. Instead of channel portion 54 overlapping a portion of 
the side surface of sheet 12, as in attaching members 14, 16 and 14A, 
channel portion 54 is generally aligned with the edge of sheet 12 in the 
general plane of the sheet material. As above, channel portion 54 includes 
top wall 60, bottom wall 62, closed sidewall 64 and retaining flanges 66, 
68 which extend toward one another to define opening 70 leading to 
interior channel 72 defined by the top, bottom and sidewalls. As with 
channel portion 28 and attaching members 14, 16 and 14A, the ends of 
channel portion 54 are open to allow insertion of roller R which again, is 
vertically elongated as well as being elongated in the lengthwise 
direction and generally parallel to rectilinear lower glass edge 12. 
Opening 70 extends generally parallel to channel 72, as well as to the 
edge of glass 12, as shown. In order to enhance adherence of attachment 
member 52 to glass 12, at least one of the securing flanges, in this case 
flange 58, has a thickness which is increased with respect to the 
thickness of the other securing flange 56 in order to provide increased 
curing heat for the primer applied under the molding material thereby 
enhancing overall adhesion strength for the gasket to glass after molding. 
As shown in FIGS. 7 and 9, the fourth embodiment 80 of the window panel 
assembly incorporating modified attachment members 82, 84 is illustrated. 
As in embodiment 10, attachment members 82, 84 are spaced apart along the 
lower edge of sheet 12 and are each adapted to receive one of the rollers 
from the window regulator mechanism. Each attachment member 82, 84 
includes an attachment flange 86 projecting outwardly away from the 
peripheral edge of sheet 12 and a pair of molded, securing flanges 88, 90 
which extend over the side surfaces of glass sheet adjacent its edge 
toward the center of the sheet to envelope and encapsulate the peripheral 
edge in the location of the attachment member. Securing flanges 88, 90 may 
be increased in thickness to enhance the curing heat for the molding 
material to enhance adhesion strength. Each of the attachment flanges 86 
include an elongated opening 92 extending entirely through the flange for 
receipt of and access by a roller mechanism from a window regulator from 
either side thereof. Opening 92 is elongated in the lengthwise direction, 
is rectilinear, and generally extends parallel to the edge of glass 12. At 
either end of each elongated opening 92 are enlarged, circular areas 94 
which allow the retaining F flanges adjacent either side of the roller R 
in window regulator mechanism M to be pushed through the opening followed 
by rolling the roller along the length of opening 92 into position. Such 
insertion of the roller mechanism after assembly avoids the necessity of 
having to assemble the roller in the slot or opening 92 and saves 
considerable installation time. As with attachment members 14, 16, members 
82, 84 are each preferably molded from RIM polyurethane material and form 
connecting cavities extending to connecting portions 18a, 20a and gasket 
portions 18, 20, as described above. The typical extremes of the paths of 
travel of the rollers in window regulator mechanism M are shown in phantom 
in FIG. 7 for this embodiment. 
With reference to FIG. 8, an additional embodiment 100 of the window panel 
assembly is shown including a one-piece attachment member 102 having a 
cross section substantially similar to that of either attachment member 82 
or 84, as shown in FIG. 9. As with attachment members 82, 84, member 102 
includes an attachment flange 104 in which is formed an elongated slot or 
opening 106 extending entirely through flange 104. Member 102 is secured 
to the lower edge of glass sheet 12 by means of securing flanges 108, 110 
which are substantially similar to flanges 88, 90 and may have an 
increased thickness to enhance adhesion strength, as described above. Each 
of the closed ends of opening 106 includes an enlarged circular area 112 
similar to area 94 to allow insertion of the roller assembly R without 
prior disassembly, as described above. 
Because of the overall length of opening 106 in attachment member 102, and 
to safeguard against deflection of the lower surface of opening 106 when 
engaged by either of the roller assemblies from the window regulator 
mechanism, an integrally molded support or connector 114 may optionally be 
formed extending across the opening 106 generally perpendicular to the 
extent of the opening to connect the upper and lower areas of the 
attachment flange 104. Inclusion of support 114 depends on the length of 
opening 106 and the resiliency of the molding material from which 
attachment member 102 is formed. As described above, the normal range of 
motion for either roller in window regulator assembly M is generally 
toward either closed end of opening 106, as shown in phantom in FIG. 8. 
Hence, support connector 114 is formed generally in the center of opening 
106 intermediate the closed ends thereof in a position which does not 
interfere with the range of travel of the rollers in mechanism M. As 
above, attachment member 102 may be molded from RIM polyurethane or other 
polymeric materials and is formed by a cavity which leads to connecting 
portions 18a, 20a and gaskets 18, 20 in the manner described above. 
Two additional embodiments of the window panel assembly including 
attachment members similar to members 82, 84 and 102 are shown in FIGS. 
10-13 but including attachment flanges which are offset from the general 
plane of the glass sheet 12. In embodiment 120, shown in FIGS. 10 and 11, 
a pair of spaced attachment members 122, 124 are molded directly on the 
lower edge of sheet glass 12. Each attachment member includes an 
attachment flange 126 including an elongated opening 128 having enlarged 
circular ends 130, as well as a pair of securing flanges 132, 134, on 
opposite sides of the glass sheet periphery. At least one of the securing 
flanges such as flange 134 includes an elongated area 136 of increased 
thickness to increase adhesion strength, as described above. As shown in 
FIG. 11, attachment flange 126 is offset from the plane of sheet 12 toward 
securing flange 132 in order to provide better positioning for receipt of 
roller R of window regulator mechanism M. As with embodiments 80 and 100, 
enlarged openings 130 are adapted to receive roller assembly R without 
disassembly prior to movement of the roller into opening 128 thereby 
decreasing assembly time. 
A one-piece version of embodiment 120 is shown at 140 in FIGS. 12 and 13. 
In this embodiment, a one-piece attachment member 142 is molded directly 
on the lower edge of glass sheet 12 as with embodiments 14A, 50 and 100. 
As with embodiment 120, attachment member 142 includes an attachment 
flange 144 which is offset from the general plane of sheet 12, as shown in 
FIG. 13. Flange 144 includes an elongated opening 146 having enlarged 
circular ends 148 for receipt of roller mechanisms without disassembly and 
a pair of inwardly extending securing flanges 150, 152. At least one of 
the securing flanges, in this case flange 150, includes an elongated area 
154 having an increased thickness to enhance adhesion strength. As in 
embodiment 100, a connecting support 156 may be included in the center of 
opening 146 to connect the upper and lower portions of attachment flange 
144 for additional support depending on the overall length of the opening 
146 and the stiffness an resiliency of the molding material from which 
attachment member 142 is formed to support the roller mechanisms. As 
above, support 156 does not interfere with the normal range of travel of 
the rollers in opening 146 which is shown by the positions of the rollers 
in phantom at either end of the opening in FIG. 12. 
As shown in FIG. 13, one form of a roller assembly 160 on a regulator 
mechanism is shown and is especially useful with the elongated openings 
92, 106, 128 and 146 of embodiments 80, 100, 120 and 140. Roller assembly 
160 includes a cylindrical support 162 formed integrally with an enlarged 
head 164 on one end and a planar, circular washer or flange 166 on the 
opposite end. Head 164 and flange 166 confine a polymeric plastic bushing 
168 which is rotatably fitted around the cylindrical, circumferential 
surface of support 162 for engagement with the lower surface of opening 
146 in attachment member 142. Support 162 is threadedly secured to a 
support/mounting bar 170 by means of a headed securing bolt 172. In the 
present invention, roller assembly 160 may be assembled prior to insertion 
in elongated opening 146 followed by bushing the conically shaped head 164 
through one or the other of openings 148 at either end of opening 146 
until bushing 168 is aligned with the top and bottom surfaces of opening 
146 and thereafter moved into the main portion of opening 146 intermediate 
openings 148. 
In each of the embodiments of the molded attachment members, the openings 
for receiving the window regulator mechanisms have been described as being 
substantially rectilinear. However, it is within the scope of the present 
invention to form the channel portions of the openings in any of the 
embodiments in a curved form to change the rate or the direction of motion 
of the window assembly as it is being raised and lowered. In addition, the 
shape of the channels or openings can be changed to accommodate desired 
rollers or other mechanisms by adjusting the shape and dimension of the 
mold cavities. Also, for embodiments 10, 80 and 120, it would be possible 
to combine different attachment members on one window assembly, such as 
members 14 and 84 or 124. Also, for members 14, 16, the openings 42 can 
face in opposite direction if desired. 
FIG. 14 illustrates another window assembly panel 180 having a molded, 
elongated attachment member 182. In FIG. 14, attachment member 182 
includes an attachment flange 184 in which is formed an elongated slot or 
opening 186 extending entirely through flange 184. Member 182 is secured 
to the lower edge of glass sheet 12 by means of securing flanges 
substantially similar to flanges 88, 90 described above with reference to 
FIG. 9. Each of the enclosed ends of opening 186 includes an enlarged 
rectangular opening area 188 to receive a glide assembly G in a similar 
fashion to that described above in relation to rollers R in FIG. 8. 
To prevent deflection of the lower surface of opening 186 when a downward 
force is applied by glide assembly G, opening 186 may have an integrally 
molded support or connector 190 generally perpendicular to the opening and 
connecting the upper and lower areas of attachment flange 184. In the 
alternative, the lower portion of attachment flange 184, below opening 
186, may have a rigid member or stiffener 192 which extends substantially 
along the length of the attachment member and slightly beyond end 188 of 
opening 186. Rigid member 192 may be molded within the attachment member 
having its ends bent upward and around ends 188 of opening 186 in 
attachment member 182 to provide additional strength. Rigid member 192 may 
be a bar or rod made from a variety of materials such as steel, aluminum 
or some types of plastic. 
As shown in FIG. 15, a glide assembly 194 may be used with attachment 
member 182. Glide assembly 194 includes a slide 196 having a solid, 
generally rectangular body 198 including an upper channel 200 and a lower 
channel 202 defined by flanges 204 extending outwardly and substantially 
parallel with sides 206 of the slide. Slide body 198 has a hole 208 
extending therethrough along the shortest dimension to receive a fastener 
such as bolt or screw 212 which can be secured in a hole 216 in an arm 214 
of window regulator mechanism M by a nut 218 and washer 220. In the 
alternative, bolt or screw 212 may be received by threads in hole 216. In 
one embodiment, the width of upper and lower channel 200, 202 is slightly 
larger than the width of elongate opening 186. With slide 196 in opening 
186, flanges 204 of the slide engage the sides of attachment flange 184 to 
retain the slide within opening 186. The extremes of the travel paths of 
each slide 196 would be similar to those shown in phantom in FIGS. 7 and 
8. 
FIG. 16 is an alternate embodiment 222 of glide assembly 194 shown in FIG. 
15. In FIG. 16 a molded attachment member 224 is substantially similar to 
that described in reference to FIGS. 7-12. Attachment member 224 is molded 
along the lower edge of sheet 12 and is adapted to receive at least one 
slide 226. Attachment member 224 includes an attachment flange 228 
projecting outwardly away from the peripheral edge of sheet 12 and a pair 
of molded, securing flanges 230, 232 which extend over the side surfaces 
of glass sheet 12 adjacent its edge and toward the center of the sheet to 
envelope and encapsulate the peripheral edge in the location of the 
attachment member. Attachment flange 228 includes an elongate opening 234 
extending entirely therethrough to receive slide 226. Just as in FIGS. 
7-9, opening 234 is elongated in a lengthwise direction of attachment 
member 224, is rectilinear, and generally extends parallel to the edge of 
glass sheet 12. Instead of the enlarged circular openings 94 located at 
both ends of opening 94, 106 as shown in FIGS. 7-8, a rectangular opening 
188 is located at one or both ends of opening 234 in which to receive the 
generally rectangular body of slide 226, as shown in FIGS. 14 and 16. 
As illustrated in FIG. 16, opening 234 has an upper and a lower flange 236, 
238 extending from opening 234 inwardly along a centerline of the opening 
to define a central rail or track. Slide 226 disposed therein has an 
aperture 227 for receiving a fastener bolt 212 like that described above 
for securing regulator mechanism arm 214 thereto. Slide 226 also has an 
upper and a lower channel 240, 242 slightly wider than the upper and lower 
flange 236, 238 so as to glide thereon without binding. Flanges 244 on 
each side of channels 240, 242 nest along the exterior sides of upper and 
lower flanges 236, 238 and within elongate opening 234 so as not to 
project out of that opening thereby avoiding interference with any 
structure adjacent the window. 
FIG. 17 illustrates another embodiment 246 of a glide or slide of the 
present invention. Slide 246 has a generally rectangular body 248 having 
securing aperture 249 and upper and lower channels 250, 252 defined by 
outwardly extending, parallel flanges 254. To provide lateral centering of 
slide 246 within the opening, each flange may be bowed inward sc that 
convex surface 255 of each flange engages the attachment member to center 
the slide. As an alternative to bowed flanges 254, a leaf spring 258, with 
its convex surface bowed inwardly, may be located along channel wall 260 
of each flange 254 to center slide 246. If vertical centering is desired, 
a similar leaf spring may be disposed at the bottom of each channel and 
fixed therein so that the convex surface of the spring engages the surface 
of attachment flange 228, or flanges 236, 238 thereon. 
In each of the glide assemblies described above, one mechanism for 
fastening the slide to the arm of window regulator mechanism M included a 
bolt or screw secured by threads in the arm or by a nut and lock washer. 
Depending upon the vehicle design, the up and down movement of the 
window/panel assembly may involve considerable rotation about an axis 
perpendicular to the length of the bolt, i.e., for curved windows or those 
windows whose tracks move them outwardly to a position mounted flush with 
the vehicle body. Considerable clearance may be required between the bolt 
shank and the hole in the slide body to allow up to as much as 25.degree. 
of rotation perpendicular to the length of the bolt or screw. The 
rotational freedom may be necessary to accommodate the up and down 
movement of window assembly 10. Although not shown in the figure, the 
rotational movement between the bolt and the slide body may also be 
provided by enlarging the hole in the slide in the appropriate direction 
of rotation. However, such clearances may become excessive and result in a 
loose connection and vibration. Moreover, the loose coupling may increase 
wear on the bolt and increase the chanca of failure in the coupling, 
causing the window panel assembly to remain at that particular position, 
or fall completely open. To compensate for the rotation of the window 
panel assembly, without the loose coupling between the slide and the 
window regulator mechanism, a special coupling is desired and described 
below. 
FIG. 18 is one embodiment 260 including such a special coupling Embodiment 
260 includes a glide assembly 262 for use in connecting arm 214 of window 
regulator mechanism M to a molded attachment flange 264. Glide assembly 
262 includes a slide 266 having a generally rectangular body 268 with a 
securing aperture 269, an upper channel 270 and a lower channel 272 
defined by vertically extending flanges 274. Each channel 270, 272 has a 
convex floor 276 and sloping inner walls 278 which in effect are normal to 
convex floor 276. The angle between sloping inner walls 278 will vary and 
depend upon the amount of rotation provided between window regulator 
mechanism M and the window panel assembly when moved up and down. Convex 
surfaces 276 of channels 270, 272 engage concave surfaces defined in upper 
and lower surfaces 280, 282 of opening 284 in attachment flange 264. It is 
preferred that the width of upper and lower surfaces 280, 282 of opening 
284 be considerably narrower than the width of channels 270, 272 so that 
slide 266 may pivot in the direction of arrows A within the opening about 
its longitudinal axis L. The pivot angle of the slide may be increased by 
beveling edges 286 of upper and lower surfaces 280, 282, thus giving the 
slide maximum rotation. With the rotational movement provided by the 
convex/concave surfaces between the slide and the slot, and maintaining 
close tolerances, the slide may be coupled to the arm of the window 
regulator mechanism using a substantially rigid fastener such as the bolt 
or screw 212 in the arrangement described above without the need for 
increased clearances between the slide and fastener. Again, as with 
previous embodiments, opening 284 includes an enlarged rectangular opening 
area 188 for receipt and installation of slide 266. 
FIG. 19 is a sectional view of a generic glide assembly 290 illustrating a 
preferred embodiment of another universal joint type coupling between 
slide 292 and arm 214 of window regulator mechanism M. The slide has a 
generic rectangular body 294 (shown in phantom) and may be used in any one 
of the molded attachment members described above. As in the above 
embodiments, slide body 294 has a centrally located hole 296 extending 
transversely therethrough along the slide's shortest axis. In the instant 
embodiment, the hole defines a substantially spherical socket 298 located 
at the geometric center of the slide body. One end 300 of hole 296 
entering socket 298 may be larger in diameter than the opposite end 302 of 
the hole in order to receive a head or member 306 of a spherical coupler 
304. The diameter of end 300 of hole 296 receiving head 306 of spherical 
coupler 304 is such that head 306 may be snapped in and firmly held within 
socket 298, yet have sufficient freedom to allow head 306 to pivot within 
the socket. The opposite end 308 of spherical coupler 304 may be rigidly 
fastened to the arm of window regulator mechanism M. The spherical 
coupling between the slide and the arm of window regulator mechanism M 
allows the window attachment assembly to rotate while simultaneously 
maintaining a rigid, low noise, and responsive coupling with window 
regulator mechanism M. Body 294 of slide 292 may have excess material 
removed therefrom to make the slide lighter and more responsive. In such 
case, socket 298 will be supported by ribs or spokes coupling the socket 
to the upper and lower channels. 
With reference to FIG. 20, embodiment 320 of a glide assembly for use with 
the attachment members 322 having a C-shaped channel 324 is illustrated 
and is similar to that shown in FIGS. 2-6. Glide assembly 320 includes a 
slide 326 having a generally rectangular body with cross-sectional 
dimensions substantially equal to the cross-sectional dimensions of the 
interior of channel 224 to facilitate a free gliding motion of slide 326 
therein without binding. The rectangular body includes a hole 332 
extending therethrough along the shortest dimension and aligned with 
opening 334 in side of channel 324. Slide 326 may be coupled to arm 214 of 
window regulator mechanism M by way of a fastener such as a bolt or screw 
212 described above and extending through hole 332 in the slide. It would 
be desirable for the head of the bolt or screw to be recessed within a 
hole 335 in the side of the slide so as not to interfere with the gliding 
motion of slide 326 within the channel. 
Of the various embodiments of the attachment members described above, it is 
preferred that each be molded directly onto the window or panel using a 
process called reaction injection molding (RIM). Although various plastics 
and resins may be used, such as polyvinylchloride (PVC), vinyl chloride 
acetate, and the like, it is preferred that a mixture of polyol and 
isocyanate be used. The two compounds react in an exothermic reaction and 
cure to form a polyurethane attachment member. It is preferred that the 
material have a flex modulus or modulus of rigidity approximating 30,000 
pounds per square inch. The glide assemblies, shown in FIGS. 14-20 may be 
constructed from a variety of high strength materials including resins or 
plastics. It is preferred that each slide be molded from acetal 
copolymer-based resin such as CELCON made by the Celanese Corporation. 
Such material has a good memory and is self-lubricating to provide the 
optimum glide characteristics within the attachment member. 
The description of the invention has thus far been directed toward the 
various embodiments of the attachment members coupled to glass sheet 12, 
as well as different embodiments of the roller or glide received by the 
slots of the attachment member. The following discussion, making reference 
to FIGS. 21-27, will focus on alternate embodiments of another portion of 
the glide assembly for coupling the rollers or slides to the arm of the 
window regulator mechanism M. 
FIG. 21 shows one embodiment 340 of a cap used to interconnect a roller R 
or glide assembly G to the end of arm 214 of window regulator mechanism M. 
Cap 340 has a generally rectangular body 342 having a first or 
longitudinal axis, X, passing through ends 344, 346; a second intermediate 
axis, Y, passing through sides 348, 350; and a third and shortest axis, Z, 
passing through sides 352, 354, each perpendicular to the other. Cap 340, 
molded from polybutylene terephthalate (PBT) or similar material includes 
a cavity 356 where its interior dimensions are substantially similar to 
the exterior dimensions of regulator arm 214 and opens to the exterior of 
cap 340 through opening 358 located in the end 344 of cap 340. Cap 340 is 
adapted to be placed over the end of regulator arm 214 by sliding the arm 
into cavity 356. In one embodiment, cap 340 may be retained on the end of 
the arm by pressure or with an adhesive. In another embodiment, mechanical 
detents 360 may be employed in the cavity of the cap to engage notches 366 
formed in the sides of regulator arm 214 as shown in FIG. 22, thus 
allowing the cap to be placed on the end of the arm, but not easily 
removed. 
In FIG. 22, cap 340 is shown with cavity 356 formed therein and receiving 
one end of regulator arm 214. Located near the entrance 358 of the cavity 
at end 344 are projections or detents 360 extending into the cavity. 
Projections 360 have a gradually sloping surface 362 from end 344 toward 
end 346. A sharp break occurs at the end of the sloping surface 362 and 
forms a shoulder 364. Each projection is received in a notch 366 formed in 
the edges of arm 214 and having a shape identical to each projection. 
As shown in FIGS. 23 and 24, another embodiment 370 of a cap for use on the 
end of regulator arm 214 is illustrated. As in the previous embodiments, 
cap 370 has a generally rectangular, but slightly tapered body 372 
enclosing a cavity 374 for receiving the end of regulator arm 214. The cap 
has a hole 376 passing through one side 378 and aligned with hole 216 
passing through the end of regulator arm 214 when the cap is in place. A 
spring 380, preferably formed from spring steel, located on side 378 of 
the cap is positioned so that one or a first end 382 is fixed to side 378 
of the cap by an anchor 384 and the opposite or second end 386 passes 
through hole 376 and is located within hole 216 in the regulator arm 214. 
End 386 of spring 380 engages the side of hole 216 and prevents the cap 
from inadvertently coming off the end of the regulator arm. The cap may be 
slidably removed by withdrawing end 386 of the spring from hole 216. 
Cap 370 has a pin or stud 388 extending from side 390 opposite side 378 
containing the spring. The shape of the stud will vary depending upon 
which of the above embodiments are employed. In the embodiments employing 
a bolt and nut arrangement for coupling the glide to the arm of the 
regulator mechanism, such as shown in FIG. 15, stud 388, as shown in FIG. 
25, may have a frusto-conical flange 392 at its tip 394 for locking the 
pin in the slide. Embodiments of the panel assembly where the slide pivots 
about a spherical coupler, pin or stud 388 may have a ball 396 formed at 
tip 394, as shown in FIG. 26. 
As shown in FIG. 27, another embodiment 400 of a cap has a two-piece body 
402 comprised of a first or front portion 404 and a second or back portion 
406 both preferably molded from metal resin such as CELCON. Front portion 
404 has essentially the same basic shape as the previously described 
embodiments of caps with the exception that cavity 408 is exposed along 
one side 410. A plurality of posts 412 extend from the cap perpendicular 
to side 410 and include barbs to engage and lock in hole or slots 414 
defined in the second or back portion 406. The posts bring back portion 
406 in registered alignment with front portion 404 and close the cavity 
408 and form the entrance 416. The back portion has an integrally formed 
spring 418 adapted to engage hole 216 in the end of regulator arm 214 when 
the cap is in place. Thus, integral spring 418 prevents the unintentional 
removal of the cap from the end of the regulator arm. 
As briefly mentioned above, one of the objects and advantages of the 
invention is the ease of assembly existing in originally manufactured 
vehicles. A further advantage is a reduction in inventory accounting 
because the panel assembly may be shipped preassembled. That is, the 
window panel, attachment member, and the glide assembly may be 
preassembled before shipping to the manufacturer, dealer or body shop. The 
window or panel assembly, having one or more attachment members molded to 
the lower edge thereof, may be selected for the appropriate vehicle. The 
spherical coupler or ball stud extending from the molded cap may be 
snapped into the socket of the slide before placing the slide within the 
slot of a panel attachment member. The glide assembly, consisting of the 
slide and spherical coupler and cap, is coupled to the attachment member 
by inserting the slide in the enlarged opening located at one or either 
end of the attachment member. The slide is moved far enough along the slot 
and may be temporarily retained thereon so as not to be lost in shipment. 
Before the panel or window assembly is inserted in the vehicle, location 
of the one or more slides is determined by matching the holes in the slide 
with the access holes provided in the door panel. In the alternative, the 
attachment member may be pre-marked for the location of the slides for a 
particular vehicle. The window or panel assembly is lowered into the door 
panel opening with the glide assembly appropriately located such that the 
cap may be locked into position on the ends of the regulator arms. To 
remove the window or panel assembly, the operator may simply pop or unsnap 
the spherical coupler from the socket in each slide and remove the window 
or panel assembly. In the alternative, the operator may remove the cap 
from the end of the regulator mechanism before removing the window panel. 
Although the assembly of the window panel was described with reference to 
the spherical coupling with the slide, it is understood that other 
coupling mechanisms such as bolts or flanged pins may be used equally as 
well. Moreover, although the above description was made with reference to 
a single attachment member located along the lower edge of the window or 
panel assembly, it is considered to be within the scope of this invention 
that more than one attachment member be provided. 
For each of the various embodiments of the cap described above, each is 
intended to offer a rapid adaptation of the end of the window regulator 
arm to a glide located in the attachment member molded to the rim of the 
glass panel. The caps are intended to be easily installed over the ends of 
the window regulator mechanisms and coupled to the slide in gliding 
engagement with the slots of the window attachment member. As the window 
regulator mechanism is moved, the coupling through the cap to the glide 
causes the window panel to move to the desired position. 
While several forms of the invention have been shown and described, other 
forms will now be apparent to those skilled in the art. Therefore, it will 
be understood that the embodiments shown in the drawings and described 
above are merely for illustrative purposes, and are not intended to limit 
the scope of the invention which is defined by the claims which follow.