Abstract:
A windshield wiper assembly for a vehicle includes a wiper motor. The wiper motor has a housing having a top surface and a side surface, a projection projecting from the top surface, a mounting bracket integrally extending from the side surface, and a rib integrally extending from the top surface and between the projection and a longitudinal end of the mounting bracket. Advantageously, the rib enhances the robustness of the housing so that it is more tolerant of stresses experienced during use.

Description:
BACKGROUND 
       [0001]    The present invention relates to a vehicle windshield wiper assembly. 
         [0002]    Referring to  FIGS. 6 and 7 , a conventional windshield wiper assembly  200  typically includes a wiper motor  210 , one or more wiper blades secured to wiper arms, and a pivotable linkage mechanism therebetween. 
         [0003]    The wiper motor  210  has a housing  211  and a motor  220  which is connected to the housing  211 . The housing  211  has a top surface  212  and a side surface  213 . A projection  214  extends from the top surface  212 . The projection  214  pivotally supports an output shaft  230  of the wiper motor  210 . When the wiper motor  210  is driven, the output shaft  230  rotates in a predetermined direction r 1 . 
         [0004]    The wiper motor  210  has a mounting bracket  215  integrally formed with the side surface  213 . The mounting bracket  215  is attached to a bar when mounted within a vehicle. The wiper assembly  200  is mounted to the vehicle at mounting parts  250 . A link mechanism  260  which is attached to the output shaft  230  moves back and forth in predetermined ranges r 2 , r 3  and r 4  due to rotation of the wiper motor  210 . As a result, the wiper arms reciprocate along a windshield. 
         [0005]    When the wiper motor  210  rotates while under the influence of obstacles such as snow, sleet, and the like at or near the end-of-stroke reverse positions, the load on the link mechanism  260  becomes high. As a result, each part of the wiper assembly  200  undergoes considerable stress. In particular, the housing  211  of the wiper motor  210  becomes highly stressed at the top surface  211 , the side surface  212  and the mounting bracket  215 . 
       SUMMARY 
       [0006]    One aspect of the invention overcomes many limitations and disadvantages of a conventional windshield wiper assembly for use in connection with the vehicle. For example, this windshield wiper assembly includes a wiper motor including a housing having a top surface and a side surface, a projection projecting from the top surface, a mounting bracket integrally extending from the side surface, and a rib integrally extending from the top surface and from the projection to a longitudinal end of the mounting bracket. Advantageously, by having the rib on the housing, the housing is more robust and stress resistant than the conventional windshield wiper assembly. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a perspective view of a cut away cowl cover plate which shows a windshield wiper assembly in the mounted state according to an embodiment of the present invention. 
           [0008]      FIG. 2  is a front view of a wiper windshield assembly according to an embodiment of the present invention. 
           [0009]      FIG. 3  is a perspective view of a wiper motor of the present invention. 
           [0010]      FIG. 4  is a perspective view of a gear housing of the wiper motor to the present invention. 
           [0011]      FIG. 5A  is a side view of the gear housing as seen from the direction of an arrow  5 A in  FIG. 4 . 
           [0012]      FIG. 5B  is a sectional view of the gear housing taken along line  5 B- 5 B in  FIG. 4 . 
           [0013]      FIG. 6  is a front view of a windshield wiper assembly according to the related art. 
           [0014]      FIG. 7  is a perspective view of a wiper motor according to the related art. 
       
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0015]    Embodiments of the invention will be explained with reference to the drawings. 
         [0016]    As shown in  FIG. 1 , a vehicle  10  includes a windshield  11  and a body panel  12 . The body panel  12  includes a cowl box  13  and a cowl cover plate  14  which covers the cowl box  13 . A windshield wiper assembly  100  is mounted within the cowl box  13 . 
         [0017]    As shown in  FIGS. 1 to 3 , the wiper assembly  100  includes a first pivot assembly  110 , which includes a first pivot shaft  111 , a first pivot lever  112 , a first shaft supporting portion  113 , a first pivot cap  114 , a first bar coupling portion  115 , and first body mounting parts  116 ,  116 . 
         [0018]    Also, the wiper assembly  100  includes a second pivot assembly  120 , which includes a second pivot shaft  121 , a second pivot lever  122 , a second shaft supporting portion  123 , a second pivot cap  124 , a second bar coupling portion  125 , and second body mounting parts  126 ,  126 . Further, the wiper assembly  100  includes a bar  130  and a link mechanism  140 . 
         [0019]    Details of each of these structures are described below. 
         [0020]    The first and second pivot shafts  111  and  121  are preferably formed of metal, and have an elongated cylindrical shape. The first and second pivot levers  112  and  122  are preferably formed of metal, and have a rectangular and thin plate shape. 
         [0021]    A first end of the first pivot shaft  111  is coupled to a first end of the first pivot lever  112 . A first end of the second pivot shaft  121  is coupled to a first end of the second pivot lever  122 . 
         [0022]    The first and second shaft supporting portions  113  and  123  are preferably formed of metal or plastic, and have a cylindrical bore shape. The first pivot shaft  111  is inserted into the first shaft supporting portion  113  so that the first pivot shaft  111  is pivotally supported by the first shaft supporting portion  113 . The second pivot shaft  121  is also inserted into the second shaft supporting portion  123  so that the second pivot shaft  121  is pivotally supported by the second shaft supporting portion  123 . 
         [0023]    The first pivot cap  114  is attached to the first pivot shaft  111  or the first shaft supporting portion  113  so that grease is encased by the first pivot cap  114 . The second pivot cap  124  is attached to the second pivot shaft  121  or the second shaft supporting portion  123  so that grease is encased by the second pivot cap  124 . By providing the first and second pivot caps  114  and  124 , fluid (e.g., rain water, melting snow, washing fluid, and the like) is prevented from splashing on or encroaching between the first pivot shaft  111  and the first shaft supporting portion  113 , and between the second pivot shaft  121  and the second shaft supporting portion  123 . 
         [0024]    The first and second bar coupling portions  115  and  125  are preferably formed of metal or plastic, and are integrally formed with the first and second shaft supporting portions  113  and  123  so that they project outwardly from the sides of the first and second shaft supporting portions  113  and  123 . The first and second bar coupling portions  115  and  125  are generally an elongated cylinder, for example, 23 mm in diameter, with a circular cross-section, and are coupled to both ends of the bar  130  by any suitable method of mounting such as press-fitting, swaging, or via threaded fasteners. 
         [0025]    The first and second body mounting parts  116  and  126  are preferably formed of metal or plastic, and are integrally formed with the first and second shaft supporting portions  113  and  123 . The first and second body mounting parts  116  and  126  are mounted on the cowl box  13  by, for example, bolts. As such, the first and second bar coupling portions  115  and  125  are maintained stationary relative to the cowl box  13  while the first and second pivot levers  112  and  122  are pivotable about the first and second pivot shafts  111  and  121 . 
         [0026]    The bar  130  is preferably formed of metal, and is generally an elongated straight cylinder, for example, 25 mm in diameter, with a circular cross-section that is cut to a predetermined length, for example, 300 mm. 
         [0027]    The first bar coupling portion  115  is coupled to a first end  130   a  of the bar  130  by, for example, press-fitting or swaging. Also, the second bar coupling portion  125  is coupled to a second end  130   b  of the bar  130  by, for example, press-fitting or swaging. 
         [0028]    As illustrated, the first and second bar coupling portions  115  and  125  may be inserted within both ends to enhance the interconnection therebetween. 
         [0029]    As shown in  FIG. 2 , the link mechanism  140  includes first and second link rods  141  and  142 . The first and second link rods  141  and  142  are preferably formed of metal although other materials may substitute therefor. The link mechanism  140  is pivotally connected to the first and second pivot levers  112  and  122 . 
         [0030]    As shown in  FIG. 2 , the second end  112   b  of the first pivot lever  112  is pivotally connected to a first end  141   a  of the first link rod  141 . The second end  122   b  of the second pivot lever  122  is pivotally connected to a second end  141   b  of the first link rod  141 . The second end  122   b  of the second pivot lever  122  is pivotally connected to a first end  142   a  of the second link rod  142 . 
         [0031]    As shown in  FIGS. 2 to 5B , the wiper motor  150  includes a motor  151 , and a housing  152  which is coupled to the motor  151 . The wiper motor  150  is directly mounted on one side of the bar  130 , and between the first and second bar coupling portions  115  and  125  by, for example, bolts and nuts. When the wiper motor  150  rotates in the predetermined range R 1 , the first and second levers  112  and  122  move in predetermined ranges R 2 , R 3  and R 4 . Further, the first and second link rods  141  and  142  move back and forth with the first and second levers  112  and  122 . 
         [0032]    The housing  152  is preferably formed of metal or plastic, and is integrally formed with a top surface  153 , a side surface  154 , a projection  155  and a mounting bracket  156 . The top surface  153  has a shape which is a combination of a semicircle and a square. 
         [0033]    The top surface  153  includes a projection  155  which has a longitudinal cylindrical bore extending therethrough. As shown in  FIGS. 5A and 5B , a first direction A is defined as a top direction for providing relative orientation of the top surface  153  in  FIG. 5A . In this case, the direction A is defined as a direction which the projection  155  extends from the top surface  153 . Also, a second direction B is defined as a bottom direction and is in an opposite direction relative to the first direction A. The side surface  154  extends from the edge of the top surface  153  in the second direction B. 
         [0034]    The projection  155  is integrally formed with the housing  152 . The projection  155  has a longitudinal cylindrical shape and extends from the top surface  153  in the first direction A. The projection  155  pivotally supports an output shaft  160 . The projection  155  has, for example, a height of approximately 26 mm from the top surface  153 . 
         [0035]    The mounting bracket  156  is integrally formed with the housing  152  and is mounted to the bar  130 . The mounting bracket  156  extends from the side surface  154 . The mounting bracket  156  includes a generally semicylindrical surface  156   a.  The bar  130  is mounted onto the semicylindrical surface  156   a,  secured the mounting bracket  156  to the bar  130  by bolts  156   b  and nuts. 
         [0036]    The mounting bracket  156  includes first and second top end surfaces  156   b   1  and  156   b   2  which lay in a plane perpendicular to the first direction A. The first top end surface  156   b   1  is located next to the side surface  154 . The second top end surface  156   b   2  is spaced apart from the first top end surface  156   b   1 . An inside edge of the second top end surface  156   b   2  is approximately 25.1 mm from an inside edge of the first top end surface  156   b   1 . 
         [0037]    Further, the mounting bracket  156  includes first and second longitudinal end surfaces  156   e   1  and  156   e   2 . The first and second longitudinal end surfaces  156   e   1  and  156   e   2  lay in planes perpendicular to the longitudinal direction of the mounting bracket  156 . 
         [0038]    The first longitudinal end surface  156   e   1  is located near the side surface  154 . The second longitudinal end surface  156   e   2  is located on the opposite side of the mounting bracket  156  relative to the first longitudinal end surface  156   e   1 . The first longitudinal end surface  156   e   1  is approximately 77 mm from the second longitudinal end surface  156   e   2 . 
         [0039]    As shown in  FIGS. 3 to 5B , the mounting bracket  156  also includes a boss  156   c  on the semicylindrical surface  156   a.  The boss  156   c  is located at a center of a long side of the mounting bracket  156 . The boss  156   c  extends from the semicylindrical surface  156   a  in the first direction A. The boss  156   c  has a height of approximately 3 mm from the semicylindrical surface  156   a . The boss  156   c  is approximately 62 mm from the center axis of the projection  155 . When the bar  130  is mounted on the mounting bracket  156 , the boss  156   c  inhibits longitudinal movement of the bar  130 . 
         [0040]    The mounting bracket  156  includes four projections  156   d  on the semicylindrical surface  156   a.  Each projection  156   d  is located at a corner among the first and second top end surfaces  156   b   1  and  156   b   2  and the first and second longitudinal end surfaces  156   e   1  and  156   e   2 . The projections  156   d  contact with an outer periphery of the bar  130 . The projections  156   d  prevent the bar  130  from rotating relative to the mounting bracket  156 . 
         [0041]    A rib  157  extends from the projection  155  to the mounting bracket  156  and extends from the top surface  153  of the housing  152  in the first direction A. The rib  157  includes a top end  157   a  and first and second side surfaces  157   b   1  and  157   b   2 . 
         [0042]    The top end  157   a  has a plane perpendicular to the first direction A. The top end  157   a  of the rib  157  and the first top end surface  156   b   1  of the mounting bracket  156  are preferably co-planar. The top end  157   a  has a height of approximately 13 mm from the top surface  153 . The top end  157   a  has a constant width of approximately 5 mm. The first side surface  157   b   1  extends from the top end  157   a  to an end surface  154   a  of the side wall  154  in the direction B. The first side surface  157   b   1  has a height of approximately 28.5 mm from the top end  157   a  to the end surface  154   a.  The first side surface  157   b   1  has two heights of approximately 13 mm and 28.5 mm. The rib  157  is integrally formed with the mounting bracket  156 . The first side surface  157   b   1  is located on the side of a border between the top surface  153  and the side surface  154 . The second side surface  157   b   2  is located on an opposite side of the first side surface  157   b   1 . The first and second side surfaces  157   b   1  and  157   b   2  are parallel curves. The first side surface  157   b   1  has a radius of approximately 35 mm. The second side surface  157   b   2  has a radius of approximately 30 mm. The first side surface  157   b   1  is approximately 5 mm from the second side surface  157   b   2 . 
         [0043]    The first side surface  157   b   1  is coextensive with the longitudinal end surface  156   e   1 . The rib  157  also extends from the top surface  153  to the end surface  154   a.  The first side surface  157   b   1  has a common surface with the first longitudinal end surface  156   e   1 . 
         [0044]    The opposite rib  158  is located at an opposite side of the rib  157  and is essentially aligned therewith. The opposite rib  158  includes a first opposite rib  158   a  having a common plane with the top end  157   a,  and a second opposite rib  158   b  which inclines from the projection  155  to the first opposite rib  158   a . The first opposite rib  158   a  has a constant width of approximately 5.5 mm. The first opposite rib  158   a  has a height of approximately 7.5 mm from the top surface  153 . The second opposite rib  158   b  has an angle of approximately 155 degrees relative to the first opposite rib  158   a.  The opposite rib  158  extends from the projection  155  to the housing edge  153   a.    
         [0045]    Reinforcement ribs  159  are located on the top surface  153 . The reinforcement ribs  159  extend radially outwardly from the projection  155  in a spoke-like manner. The reinforcement ribs  159  integrally extend from the top surface  153  in the first direction A, and radially extend around the projection  155  between the rib  157  and the opposite rib  158 . In this embodiment, the reinforcement ribs  159  include four ribs and extend from the projection  155  at angles about equal to adjacent ribs  159 . Each of the reinforcement ribs  159  has a generally triangular bar shape. Each reinforcement rib  159  has an angular range from about 20 degrees to about 45 degrees. Each reinforcement rib has a width of approximately 5 mm. 
         [0046]    When the wiper motor  150  rotates in the presence of obstacles (e.g., snow and the like) at or near the end-of-stroke reverse positions, the housing  152  of the wiper motor  150  is resistant to high stresses among the top surface  153 , the side surface  154  and the mounting bracket  156 . 
         [0047]    The windshield wiper assembly being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be apparent to one of ordinary skill in the art are intended to be included within the scope of the following claims.