Abstract:
A windshield wiper structural assembly and a method of forming the same is disclosed. The structural member is generally comprised of an elongate tubular component, which is bent to the desired configuration. The pivot mechanisms ( 8, 10 ) are designed for application to the exterior surface of the tubular component, whereupon they are clamped to the tubular component where they are retained. The clamping is done by wire clips which are crimped around the pivot mechanisms ( 8, 10 ). Pins can also be driven through the housings and the tubular component to prevent rotation of the housings.

Description:
[0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/444,921 filed Feb. 4, 2003, the complete disclosure of which is hereby expressly incorporated by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The subject invention relates to windshield wiper assemblies and, in particular, the structural frame, which embodies the drive and pivot mechanism for windshield wiper systems.  
         SUMMARY OF THE INVENTION  
         [0003]    Windshield wiper systems commonly include a structural mechanism, which is mounted to the vehicle, which includes a bracket for mounting an electric motor for driving the windshield wiper system, pivot mounts for pivotally mounting pivot pins for the wiper blade rotation, and a linkage mechanism between the motor and the pivot pins, which drive the blades. Several different systems are available.  
           [0004]    One such system includes stamped and formed elongate brackets having mounting feet for mounting to the vehicle, and a pivot mechanism having a bushing or bearing positioned along the length of the bracket, where the wipers should be mounted. A pivot pin will be positioned in the bearing and will be connected to the linkage, which causes the pivotal movement of the wiper blades.  
           [0005]    Another assembly is known, which includes a tubular member having mounted at its ends cast or forged pivot mechanisms, whereby the end is substantially cylindrical in cross-section and can be placed in the tubular end and crimped thereto. Each of the castings includes a mounting area for receiving the pivot pin to which the windshield wipers can be connected. Such a device is shown in U.S. Pat. No. 5,536,1 00.  
           [0006]    There are several drawbacks to the design mentioned in U.S. Pat. No. 5,536,100. First, for each different configuration, a different cast member is required, and in fact, a different cast member is required for opposite ends of the same assembly. Also, in the event that four pivot pins are located in the same assembly, then two of the interior pivot pins require a “T-configuration,” such that two ends of the cast pivot pin housing are crimped to the tubes. This means that the device can only be placed at ends of the tube. Naturally, the tube could be cut in several locations, and several couplings crimped, however this requires accuracy in location and at the same time damages the structural integrity of the tubular member itself.  
           [0007]    It should be also be appreciated that many different configurations of the wiper blade mechanisms are necessary, given the various sizes and configurations of vehicles, particularly trucks, and in fact in some instances, different configurations of the assemblies are required for different options within the exact same vehicle. It should also be appreciated that in some instances, two pivot pins are positioned along the length of the tubular member, and in some cases, four pivot pins are mounted, depending upon the geometry of the wiping pattern, and the size of the windshield to which the assembly applies.  
           [0008]    Thus, given the nature of the assembly configuration, the number of wiper blades involved, and the mounting of the assembly, it should be readily apparent that numerous cast pivot pin housings will be required to accommodate the variety of assemblies. Thus, the object of the invention is to improve upon the various assemblies mentioned above.  
           [0009]    The objects have been accomplished by providing a windshield wiper assembly, comprising at least one elongate tubular frame member, and a plurality of pivot pin housing members. Each housing member has a flange portion having an open surface for mounting to an exterior surface of the tubular frame member and a pin mounting portion. Retaining means retain the pivot pin housings to the tubular frame member.  
           [0010]    Preferably, the open surface is arcuate in cross section to substantially conform to the outside diameter of the elongate tubular frame member The open surface includes elongate ribs, having an edge for gripping the outer surface of the elongate tubular frame member. The flange portion is generally rectangular in configuration, where the arcuate open surface is configured on an elongate surface of the rectangular shape. The pin mounting portion is configured transversely to the elongate surface of the rectangular shape.  
           [0011]    The retaining means is defined by a clamp assembly having at least one clip portion, which surrounds the elongate tubular frame member and the pivot pin housing member, retaining them together. The clamp assembly is comprised of two clip portions, which flank the pin mounting portion, and which circumscribe the combination of the elongate tubular frame member and the pivot pin housing member. The pivot pin housing member, on a face opposite the arcuate open surface, has indentations, and the two clip portions have free ends which are crimped into the indentations. The windshield wiper assembly further comprises piercing pins extending through the flange portion and extends into the elongate tubular frame member. The elongate tubular frame member includes mounting members to mount the assembly. The mounting members are defined by a portion of the elongate tubular member, flattened and formed with an aperture therethrough.  
           [0012]    In another form of the invention, a method of forming an automotive wiper assembly, comprises the steps of providing a tubular structural component, providing the tubular structural component with the desired configuration, providing a pivot pin mounting housing having an open mounting face, applying the pivot pin mounting housing to the exterior surface of the tubular structural component, and retaining the pivot pin mounting housing to the tubular structural component.  
           [0013]    The retaining step is provided by clamping the pivot pin mounting housing to the tubular structural component. The clamping is provided by wire clips being formed around the exterior of the tube and around the pivot pin mounting housing. The method further comprises the step of forming apertures in the outside face which is opposite the mounting face, and the free ends of the wire clips are crimped into the apertures. The tubular component is provided with a cylindrical cross-section. The method further comprises the step of driving pins through the pivot pin housing, and radially into the tube, to prevent rotation of the pivot pin housing.  
           [0014]    Preferably, the tubular component is bent to define the desired configuration. The pivot pin housings are applied to the tubular component distant from the ends of the tube. The free ends of the tube are flattened into mounting flanges and mounting apertures are provided through the flanges.  
           [0015]    The invention will now be described with reference to the drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 is a perspective view of the wiper assembly poised relative to a windshield with which it would operate;  
         [0017]    [0017]FIG. 2 is an enlarged view of the linkage mechanism;  
         [0018]    [0018]FIG. 3 is an enlargement of the inset shown in FIG. 1, showing a pivot pin mechanism in perspective view;  
         [0019]    [0019]FIG. 4 is a top plan view of the pivot mechanism of FIG. 3;  
         [0020]    [0020]FIG. 5 is a side plan view of the pivot mechanism of FIG. 4;  
         [0021]    [0021]FIG. 6 is a cross-section view through lines  6 - 6  of FIG. 4; and  
         [0022]    [0022]FIG. 7 is a cross-section view through lines  7 - 7  of FIG. 4;  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0023]    With reference first to FIG. 1, a linkage mechanism is shown at  2 , poised relative to a windshield  4 , with which it will cooperate. It should be understood that the linkage  2  would be mounted adjacent to the windshield in a manner well known in the automotive field. With reference to FIGS. 1 and 2, the linkage mechanism is generally comprised of a tubular structural component  6  extending from end to end, with a first pivot mechanism  8  positioned at one end, and a second pivot mechanism  10  positioned at the opposite end. A motor  12  is mounted to the tubular component  6 , having a drive connection to linkage  14 , which in turn drives linkage  16 , through yoke  18 . It should be appreciated that motor  12  is configured to cause a reciprocity motion to linkage  14 . With respect now to FIGS. 2 and 3, yoke  18  is shown driving pin  20  (FIG. 3), whereas linkage  16  drives a lever  22  which in turn drives pin  24  (FIG. 2).  
         [0024]    With reference now to FIG. 2, the various components mentioned above will be described in greater detail. As shown, tubular component  6  is shown having a generally cylindrical cross-section and having a plurality of bends. It should be appreciated that the tubular component could be a stainless steel tube, which can be easily bent, yet which is structurally rigid, and weatherproof. It should also be appreciated that any configuration could be defined, where the various bends are positioned as required to position the wiper blades relative to the windshield, or where the tubular component  6  is required to not interfere with another unrelated component. However, this tubular component will be discussed below, only by way of example to the many ways the tubular component could be manufactured and configured.  
         [0025]    With respect to FIG. 2, the tubular component first has flattened end portions  30 ,  32  having apertures therethrough for mounting purposes. Each end of the tubular component  6  includes a bend  34 ,  36 , which tends to space the assembly away from the windshield to place the wipers in proper position. The tubular component then includes straight sections  38 ,  40  to which the first and second pivot mechanisms  8 ,  10  are mounted. The tubular component then includes a generally right angled bend, defined by tubular sections  44 ,  46 , which help provide a position where motor  12  can be mounted, yet position motor  12  and linkage  14  in position with yoke  18 . Transition section  50 -merely connects the sections  40  and  46  together. It should also be appreciated that other various brackets can be provided, such as auxiliary mounting brackets  54 ,  56 , and motor mounting bracket  58 .  
         [0026]    With respect again to FIG. 2, motor  12  is shown connected to linkage  14  in a known manner, where pin  60  connects motor  12  to linkage  14 . At the opposite end, a fastener assembly  62  is provided connecting linkages  14  and  16  to yoke  18 . Yoke  18  includes a sleeve portion  64  to receive fastener assembly  62 , and a lever portion  66  connected to drive pin  20 , as best shown in FIG. 3. It should be appreciated that lever  66  could be connected to pin  20  in any known manner; lever  66  and pin  20  could be integrally cast or forged, they would be welded or press-fit, or they could be splined together. However, their connection is immaterial other than to say that the rotation of lever arm  66  causes a like rotation of pin  20 . Likewise, linkage  16  is attached to lever  22 , and lever  22  and pin  24  are attached in a manner similar to lever  66 ,  20 , such that translation of linkage  16  causes a rotation of lever arm  22  and rotation of pin  24 .  
         [0027]    With reference now to FIGS. 3-7, the pivot mechanisms  8 ,  10  will be described in greater detail. It should be appreciated that these mechanisms are identical and thus only one need be explained in detail. What differs is only their location and the pivot pin, which is mounted therethrough.  
         [0028]    As shown first in FIG. 3, the pivot mechanism  8  includes a cast housing portion  70 , which is retained to the tubular component  6  by way of retaining clips or clamps  72 , and prevented from rotating by piercing pins  74  (FIG. 6). As shown best in FIGS. 3, 4 and  5 , housing  70  includes a flange portion  76  and a pin mounting portion  78 . The flange portion  76  is generally rectangular in configuration and includes a top face  80  having recesses  82  and apertures  84 . The bearing section  86  extends transversely to the length of the housing  70 , and includes a bearing sleeve or bushing  88  press fit within the bearing section  86 . The face opposite the top face  80  is a confronting face  90  (FIG. 6) having a generally semi-cylindrical configuration. The face has longitudinally extending ridges  92 , which form gripping edges which “bite” into the tubular section  6  (FIG. 7). The housing  70  further includes a sleeve section  96  to receive a pantograph post  98 .  
         [0029]    Finally, clips  72  and pins  74  will be described in greater detail. The clamps are formed from heavy wire and are formed around the housing  70 , with ends  100  crimped into recesses  82 . This retains the housing  70  to the tubular component  6 . Pins  74  may now be driven down into aperture  84 , and through tubular component  6 , as best shown in FIG. 6. This prevents (along with ridges  92 ) the twisting of the housings  70  relative to the tubular component  6 . With all of the components as described above, the assembly of the unit will now be described.  
         [0030]    As mentioned above, the tubular component will be formed as required for the application. It should be appreciated that various and multiple configurations are possible, and that the tubular components can be formed in a typical fashion with a tube bender. Thereafter the motor  12  is mounted to its bracket  58 , whereupon linkage  14  can be positioned to motor  12  by way of fastener  60 . The linkage  14  can also be fastened at its opposite end to yoke  18 , whereupon pivot member  10  can be located along the length of tube sections  40 , and held temporarily. Link  16  is fixed at both ends, at one end by fastener member  62 , and at the opposite end by a fastener to lever  22 . This allows the pivot member  8  to be located along its corresponding section of tube  38 . Once the pivot members  8 ,  10  are in their appropriate locations, then the clamp sections  72  can be applied as described above, with the ends  100  crimped into apertures  82 . The pins  74  are then driven into the tubes  6 , to the position shown in FIG. 6. The assembly can then be applied as a unit, and installed into an automotive application.  
         [0031]    It should be appreciated that the above-described assembly has numerous advantages. Firstly, the overall assembly is more rigid, as the tubular component never needs to be severed. As mentioned above, where units are plugged into the ends of tubes, the tubes would be cut in several places, then the pivot members are clinched to the tube ends. Secondly, as the identical unit can be positioned in place, then lower inventory is required for such units, and the cost of producing them also drops. Finally, the overall cost is reduced as the assembly process is simplified.