Patent Publication Number: US-7213370-B2

Title: Window regulator

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority benefit of U.S. Provisional Patent Application No. 60/606,458 filed on Sep. 1, 2004, the disclosure of which is expressly incorporated herein in its entirety by reference. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
     Not Applicable 
     REFERENCE TO MICROFICHE APPENDIX 
     Not Applicable 
     FIELD OF THE INVENTION 
     The present invention generally relates to window regulators and, more particularly, to a gear actuated window regulator for moving a closure member such as a window from one position to another. 
     BACKGROUND OF THE INVENTION 
     Motor vehicles such as automobiles typically include a window lift assembly or “window regulator” for raising and lowering windows in doors or other body panels. These window regulators can be manual or powered. Such window regulators are also used for opening and closing other types of closure members in motor vehicles such as, for example, “sunroofs”, rear windows, and the like. Many powered closure mechanism have been proposed using a rack and pinion gear to move sliding closures in motor vehicles. See, for example, U.S. Pat. Nos. 2,115,632, 2,336,530, 4,119,341, 4,167,834, 4,235,117, 4,389,818, 4,908,988, 4,967,510, 5,537,782, and 5,577,347, the disclosure of which are expressly incorporated herein in their entireties by reference. 
     While these prior closure mechanisms may adequately open and close closure members in motor vehicles, they all require a relatively large number of parts and are relatively complex to manufacture and assemble. Additionally, there is an ongoing desire for motor vehicle components such as closure mechanisms to be smaller, lighter, and lower cost. Accordingly, there is a need in the art for an improved closure mechanism for opening and closing a closure member of a motor vehicle. 
     SUMMARY OF THE INVENTION 
     The present invention provides a closure assembly for a motor vehicle which overcomes at least some of the above-noted problems of the related art. According to the present invention, a closure assembly comprises, in combination, a closure member, a guide track, a carrier operably secured to the guide track for movement along the guide track and carrying the closure member therewith, a rack having a plurality of teeth extending along the guide track, a pinion gear carried by the carrier and having teeth engaging the rack, and a motor operably connected to the pinion gear to selectively move the closure member from one position to another. The carrier includes at least one engagement member biased into engagement with the guide track to preventing binding of the carrier with the guide track. 
     According to another aspect of the present invention, a closure assembly for a motor vehicle comprises, in combination, a closure member, a guide track, a carrier operably secured to the guide track for movement along the guide track and carrying the closure member therewith, a rack having a plurality of teeth extending along the guide track, a pinion gear carried by the carrier and having teeth engaging the rack, and a motor operably connected to the pinion gear to selectively move the closure member from one position to another. The carrier includes at least one engagement member biased into engagement with the guide track to maintain contact between the pinion gear and the rack. 
     According to another aspect of the present invention, a closure assembly for a motor vehicle comprises, in combination, a closure member, a guide track, a carrier operably secured to the guide track for movement along the guide track and carrying the closure member therewith, a rack having a plurality of teeth extending along the guide track, a pinion gear carried by the carrier and having teeth engaging the rack, and a motor carried by the carrier and operably connected to the pinion gear to selectively move the closure member from one position to another. The guide track includes a pair of flanges extending in opposite directions and the carrier includes at least two guide shoes forming channels facing one another and receiving the flanges of the guide track so that the carrier is movable along the flanges in a longitudinal direction of the guide track and relative movement between the carrier and the guide track is limited in directions perpendicular to the longitudinal direction of the guide track. Each guide shoe is provided with at least one engagement member biased into engagement with the guide track to preventing binding of the carrier with the guide track 
     From the foregoing disclosure and the following more detailed description of various preferred embodiments it will be apparent to those skilled in the art that the present invention provides a significant advance in the technology and closure mechanism for motor vehicles. Particularly significant in this regard is the potential the invention affords for providing a high quality, reliable, small and lightweight, low cost, and relatively quiet mechanism. Additional features and advantages of various preferred embodiments will be better understood in view of the detailed description provided below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and further features of the present invention will be apparent with reference to the following description and drawings, wherein: 
         FIG. 1  is an inner side elevational view of a closure mechanism mounted in a motor vehicle door according to a preferred embodiment of the present invention, wherein components are removed for clarity; 
         FIG. 2  is an enlarged inner side elevational view of the closure mechanism of  FIG. 1 ; 
         FIG. 3  is a rear elevational view of the closure mechanism of  FIG. 2 ; 
         FIG. 4  is an enlarged, fragmented, inner side elevational view of an upper portion of the closure mechanism of  FIGS. 2 and 3 ; 
         FIG. 5  is an enlarged, fragmented, outer side elevational view of an upper portion of the closure mechanism of  FIGS. 2 to 4 ; 
         FIG. 6  is an exploded perspective view of an upper portion of the closure mechanism of  FIGS. 2 to 5 ; 
         FIG. 7  is an enlarged, cross-sectional view taken along line  7 — 7  of  FIG. 2 ; 
         FIG. 8  is an enlarged, fragmented, rear elevational view, partially in cross-section, of a drive assembly of the closure mechanism of  FIG. 7 , wherein components are removed for clarity; 
         FIG. 9  is an enlarged, fragmented, rear elevational view, partially in cross-section, similar to  FIG. 8  and further showing the drive assembly of the closure mechanism of  FIG. 7 , wherein components are removed for clarity; 
         FIG. 10  is an enlarged, cross-sectional view taken along line  10 — 10  of  FIG. 4 ; 
         FIG. 11  is an end elevational view of the slide of  FIG. 10 ; 
         FIG. 12  is an enlarged, cross-sectional view similar to  FIG. 10  but showing a variation of the slide; 
         FIG. 13  is an end elevational view of the slide of  FIG. 12 ; and 
         FIG. 14  is a rear elevational view similar to  FIG. 3  but showing a closure mechanism according to a second embodiment of the present invention. 
     
    
    
     It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention. The specific design features of closure mechanisms for motor vehicles as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and clear understanding. In particular, thin features may be thickened, for example, for clarity or illustration. All references to direction and position, unless otherwise indicated, refer to the orientation of the closure mechanism illustrated in the drawings. In general, up or upward refers to an upward direction within the plane of the paper in  FIG. 1  and down or downward refers to a downward direction within the plane of the paper in  FIG. 1 . Also in general, fore or forward refers to a direction toward the front of the motor vehicle, that is, toward the left within the plane of the paper in  FIG. 1  and aft or rearward refers to a direction toward the rear of the motor vehicle, that is, to the right within the plane of the paper in  FIG. 1 . 
     DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS 
     It will be apparent to those skilled in the art, that is, to those who have knowledge or experience in this area of technology, that many uses and design variations are possible for the improved closure mechanisms disclosed herein. The following detailed discussion of various alternative and preferred embodiments will illustrate the general principles of the invention with reference to a powered closure mechanism for a window of a motor vehicle door. Other embodiments suitable for other applications, such as, for example hand-operated mechanisms, mechanisms for other types of motor vehicle closures such as sun roofs, rear windows, and the like, and/or mechanisms for other types of closures will be apparent to those skilled in the art given the benefit of this disclosure. 
     Referring now to the drawings, closure mechanisms or assemblies for motor vehicles according to the present invention are disclosed. The illustrated embodiments of the present invention are particularly adapted for opening and closing a closure member such as, for example, a sliding window or panel for motor vehicles. The term motor vehicles is used herein and in the claims to mean a powered device for carry passengers, goods or equipment such as, for example, automobiles, passenger cars and trucks, self-propelled recreational vehicles, commuter vehicles, vans and mini-vans, sport utility vehicles (SUV&#39;s), cross-over vehicles, medium and heavy duty trucks, busses, self-propelled farm, industrial and construction equipment, and the like. Additionally, the term motor vehicles is used to include off road vehicles such as, for example dune buggies, golf carts, trains, airplanes, boats, and ships and the like. 
     As shown in  FIG. 1  a closure mechanism or regulator  10  according to a preferred embodiment of the present invention is installed in a motor vehicle  12  for moving a closure member  14  between open and closed positions. The illustrated closure member  14  is a window supported by a guide frame  16 . The illustrated closure mechanism  10  raises and lowers the closure member  14  along the guide frame  16  to open and close an opening  18  in the illustrated hinged door  20  of the motor vehicle  12 . It is noted that the closure member  14  can alternatively be used to open and close any other suitable motor vehicle opening such as, for example, a roof opening, an opening in the structure of the motor vehicle, or a sliding door or panel including a backlight. 
     The illustrated closure member  14  is moved by a single regulator or closure mechanism  10  having a single rack and pinion. The illustrated closure mechanism includes  10  a guide track  22 , a rack  24  extending along the guide track  22 , a lift plate or carrier  26  securable to the closure member  14  and movable along the guide track  22  to move the closure member  14 , a pinion gear  28  carried by the lift plate  26  and engageable with the rack  24  to move along the rack  24  and the lift plate  26  along the guide track  22  when the pinion gear  28  rotates, and a motor  30  operatively connected to the pinion gear  28  for selectively rotating the pinion gear  28 . The illustrated closure mechanism  10  moves the sliding closure member  14  over a path adjacent and parallel to, but spaced-apart from, a longitudinally-extending axis  32  of the guide track  22  between a full up or closed position wherein the door opening  18  is closed (shown in  FIG. 1 ) and a full down or open position wherein the door opening  18  is at least partially open (not specifically shown). A center of gravity  34  of the closure member  14  is preferably located adjacent to the longitudinal axis  32  of the guide track  22  to reduce any unbalanced forces or torque on the guide track  22  and/or the rack  24 . The closure mechanism  10  can position the closure member  14  at any position between the full open and closed positions to vary the degree to which the closure member  14  opens/closes the door opening  18 . The illustrated closure member  14  is slightly curved and moves along a slightly curved path relative to the motor vehicle door  20  as taught in U.S. Pat. No. 4,167,834, the disclosure of which is expressly incorporated herein in its entirety by reference. It is noted however, that the closure member  14  can alternatively be substantially straight and moved along a substantially straight path (best shown in  FIG. 14 ). The closure mechanism  10  can be secured to and/or supported by the door  18  or other structure of the motor vehicle in a conventional manner. The illustrated closure mechanism  10  is secured to the door  10  with mechanical fasteners  36  located near ends of the guide track  22  but any other suitable securing means can alternatively be utilized. 
     The illustrated closure member  14  is a window has a bottom edge  38 , a first or rear side edge  40 , a second or front side edge  42 , and a top edge  44 . The top edge  44  includes a segment that is generally horizontal and forwardly extends from the first side edge  40  and a second segment that tapers downwardly from the first segment at an angle toward the second side edge  42 . The first and second side edges  40 ,  42  are parallel to each other but are skewed slightly with respect to the bottom edge  38  and are not perpendicular thereto. More specifically, the first side edge  40  forms a obtuse angle with respect to the bottom edge  38  and the second side edge  42  forms an acute angle with respect to the bottom edge  38 . The illustrated closure member  14  is curved from the top edge  44  to the bottom edge  38  and forms a concave inner surface  46  and a convex outer surface  48 . The center of gravity or mass  34  is located in a plane running through the center of mass of the closure member  14  and parallel to the side edges  40 ,  42 . The plane bisects the closure member  14  into sections of equal weight. The illustrated closure member  14  is formed of a transparent glass but can alternatively be formed of any other suitable material. 
     The closure member  14  is disposed in the door  18  that includes first and second guide slots of the guide frame  16  for guiding the first and second side edges  40 ,  42  of the closure member  14 , respectively, along a generally vertical movement path in either an upward direction to close the opening  18  in the door  20  or a downward direction to open the opening  18  in the door  20  as the closure mechanism  10  moves the closure member  14  as described in more detail hereinafter. The guide slots and frames  16  are parallel to the plane bisecting the center of mass  34  of the closure member  14 , the longitudinal axis  32  of the guide track  22 , and the side edges  40 ,  42  of the closure member  14 . The structure of the guide slots and guide frame  16  are well known in the art and will not be described in detail herein. 
     The closure mechanism  10  is best seen in  FIGS. 2 to 9 . The illustrated guide track  22  is an elongate member forming the central longitudinal axis  32  that extends within the plane bisecting the center of mass  34  of the closure member  14 . In cross section (best shown in  FIG. 7 ), the guide track  22  includes a main wall  50  and a pair of end walls  52  perpendicularly extending from ends of the main wall  50  to form an interior channel  56 . Also included in cross-section, are a pair of opposed guide flanges  54  perpendicularly extending in opposite, outward directions from the free ends of the end walls  52  so that the guide flanges  54  are in the same plane. The illustrated end walls and flanges  52 ,  54  extend the entire longitudinal length of the guide track  22 . The illustrated guide track  22  is slightly curved to match the curvature of the closure member  14 . Ends of the guide track  22  are provided with openings  58  for receiving the mechanical fasteners  36  that secure the guide track  22  to the door  20 . 
     The guide track  22  is of a flexible construction to permit the guide track  22  to bend in a direction toward and away from the side edges  40 ,  42  of the closure member  14  as well as in a direction perpendicular to the inner surface  46  of the closure member  14 . The guide track  22  is also moderately flexible in the lengthwise direction to allow the guide track  22  to bend and absorb shock as the closure member  14  reaches a fully closed or open position. The guide track  22  is maintained sufficiently rigid, however, to support the weight of the closure member  14  and to withstand torque caused by the interaction of the pinion gear  28  and the rack  24  without buckling. Thus, the guide track  22  could also be described as semi-rigid. An entirely rigid guide track  22  requires that shock be absorbed by teeth of the rack  24  and the pinion gear  28 , thus requiring a more expensive rack and pinion gear. The guide track  22  can be formed of any suitable material but preferably comprises a reinforced injection molded thermoplastic wherein the base resin (polymer) is preferably from a crystalline family like polyamide, polyacetal, or polyester. 
     The illustrated rack  24  includes a vertical row of horizontally extending teeth  60  for engagement by the pinion gear  28  as described in more detail hereinafter. The illustrated rack  24  is located at the forward end wall of the guide track channel  56  and facing in a rear direction toward the rear edge  40  of the closure member  14  and thus extends parallel to the central longitudinal axis  32  of the guide member  22 . The illustrated rack  24  is formed as a unitary, one-piece component with the guide track  22  but the rack  24  can alternatively be formed as a separate component. 
     The illustrated lift plate or member  26  supports the closure member  14  and operatively engages the guide track  22  to move along the guide track  22  to raise and lower the closure member  14 . The illustrated lift plate  26  has a generally planar main wall  62  positioned adjacent to the guide track  22  and partially covering the channel  56 . The main wall  62  forms a pair of outwardly extending wings  64  at its upper end to support and connect the closure member  14 . The illustrated closure member  14  is secured to each of the wings  64  by clamping members  66  which are secured to the wings  64  by mechanical fasteners  68  and clamp the bottom edge  38  of the closure member  14 . Thus, the closure member  14  is located directly above the lift plate main wall  62  and is secured to the lift plate  26  for movement therewith. 
     To maintain engagement between the lift plate  26  and the guide track  22 , the illustrated lift plate  26  is provided with slides or guide shoes  70  which extend about the flanges  54  of the guide track  22  so that lift plate  26  substantially surrounds the guide track  22  to interlock and secure the lift plate  26  to the guide track  22 . The illustrated lift plate  26  is provided with two slides  70  on each side but any other suitable quantity of slides  70  can be utilized. The illustrated slides  70  include an end wall  72  perpendicularly extending from the main wall  62  of the lift plate  26  (and parallel and offset from the guide track end walls  52 ) and flanges  74  perpendicularly extending from free ends of the main wall  62  (and perpendicular to the end walls  52  of the guide track  22 ) in an inward direction toward one another and toward the end walls  52  of the guide track  22 . Formed in this manner, the slides  70  form inwardly facing channels  75  on opposite sides of the lift plate  26  that are sized to receive the guide track flanges  54  therein so that the lift plate  26  can freely move in a longitudinal direction along the guide track  22  but movement of the lift plate  26  relative to the guide track  22  is limited in directions perpendicular to the longitudinal direction. 
     The pinion gear  28  is indirectly supported and carried by the lift plate  26  and is engageable with the rack  24  to move the pinion gear  28  along the rack  24  and the lift plate  26  along the guide track  22  when the pinion gear  28  rotates. The pinion gear  28  includes a plurality of teeth  76  about its outer periphery and is located within the channel  56  of the guide track  22  so that the teeth  76  are operatively engaged with the teeth  60  of the rack  24 . 
     The motor  30  is also supported and carried by the lift plate  26  and includes an output shaft  78  that is operably connected to the pinion gear  28  by suitable gearing  80 . The illustrated motor  30  is provided with suitable wire connections  82  to a suitable control module and vehicle power. The illustrated motor  30  is secured to the lift plate  26  by a housing or mounting bracket  84  secured to lift plate  26  with mechanical fasteners  86 . As best shown in  FIGS. 8 and 9 , the output shaft  78  of the motor  30  is provided with a worm gear  88  that engages a driven gear  90  within the housing  84  so that the driven gear  90  rotates upon rotation of the motor output shaft  78 . The driven gear  90  is supported by a central shaft  92  within the housing  84  that is perpendicular to the motor output shaft  78 . The central shaft  92  extends from the center of the driven gear  90  to the center of pinion gear  28  so that the pinion gear  28  rotates with the driven gear  90 . Mounted in this manner, the pinion gear  28  rotates upon rotation of the motor output shaft  78 . The motor  30  and gearing  80  can be of any suitable type such as, for example, see U.S. Pat. No. 6,145,252, the disclosure of which is expressly incorporated herein in its entirety by reference. 
     The pinion gear  28  is indirectly supported by the lift plate  26  on the first side  46  of the closure member  14  and the motor  30  is supported by the lift plate  26  on the second side  48  of the closure member  14 . The illustrated pinion gear  28  is supported immediately adjacent the inner side  46  of the closure member  14 . The outer hub of the pinion gear  28  preferably overlaps the bottom edge  38  of the closure member  14 . The illustrated motor  30  has an inside edge that is preferably as close as possible to outer surface  48  of the closure member  14  without extending beyond the outer surface  48 . 
     As best shown in  FIGS. 10 and 11 , the illustrated sliders or guide shoes  70  are provided with spring-loaded engagement or slide members  94  that maintain engagement between the sliders  70  and the end walls  52  of the guide track  22  to further maintain engagement between the rack  24  and the pinion gear  28 . Each illustrated slider  70  is provided with an elongate slot or cavity  96  located in the free edge of the slider flange  74  so that the open end of the cavity  96  faces the end wall  52  of the guide track  22 . The engagement member  94  is movably secured within the cavity  96  and a biasing or spring member  98  resiliently urges the engagement member  94  away from the slider  70  and toward the guide track end wall  52  so that the spring-loaded engagement members  70  take-up any side-to-side clearance or gap between the rack  24  and the pinion gear  28 . Additionally, the spring-loaded engagement members  70  also minimize any tendency of the closure member  14  to cock by providing a biasing force that is normal to the pinion gear and track engagement so as to urge the teeth  76  of the pinion gear  28  with the teeth  60  of the rack  24 . The illustrated biasing or spring member  98  is a wave spring but it is noted that any other suitable type or form of biasing or spring member can alternatively be utilized. 
     Because the biasing member  98  urges the engagement member  94  away from the slider or guide shoe  70  and into engagement with the guide track  22 , it is preferable to minimize friction between the engagement members  94  and the guide track  22 . This can be accomplished by coating at least one of the engagement surfaces of the engagement member  94  and the guide track  22  with a low friction material such as, for example, polytetrafluoroethylene (PTFE) or Teflon, which is a trademark of Dupont. Alternatively, the engagement member  94  or a portion thereof can be formed entirely of a low friction material such as, for example PTFE. Additionally, the engagement members  94  can be adapted for rolling contact with the guide track  22  rather than the illustrated sliding contact. Because the central plane of the closure member  14  is offset relative to the central planes of the sliders  70  and the pinion gear  28 , the illustrated lift plate  26  is provided with a pair of pads or spacers  100  on opposite sides of the guide track flanges  54  and oriented at ninety degrees to the contact of the engagement member  94  with the guide track  22  and the contact of the pinion gear  28  with the rack  24  to prevent cocking of the closure member  14 . Optionally, a suitable low friction material such as, for example, PTFE may be provided on the sliding contact surfaces or the pads  100  can be entirely formed of a low friction material such as, for example, PTFE. It is noted that the pads  100  can be eliminated if desired. Thus, the engagement members  94  and the pads  100  in conjunction with the guide track  2  provide fore-and-aft and side-to-side stability (relative to the vehicle) for movement of the pinion gear  28  as it engages and moves along the rack  24 . By providing a low friction material on the engagement members  94  and/or the pads  100 , the rack and pinion operates smoothly and the power requirement to operate the rack and pinion is reduced. 
     As best shown in  FIGS. 12 and 13 , the engagement members  94  can alternatively be in the form of at least two vertically spaced apart buttons with the biasing or spring members  98  in the form of coil springs disposed in the spaced apart cavities  96 . The coil springs can be cylindrical or conical depending on the biasing force required by the application requirements. This variation illustrates that the spring-biased engagement members  94  can have other forms. 
     When the operator desires to move the closure member  14 , the operator presses an operator input device (not shown) in the required direction for a predetermined time interval and then releases the device. The device sends a signal to a control module (not shown) that in turn sends a signal to a switch which provides electrical current to the motor  30  so that the motor output shaft  78  rotates in one direction or the other as desired. Rotation of the motor output shaft  78  rotates the worm gear  88  which in turn rotates the driven gear  90 . The pinion gear  28  rotates with the driven gear  90  through the shaft  92 . As the pinion gear  28  rotates it moves along the rack  24  and moves the lift plate  26  and the closure member  14  secured thereto. This permits the closure member  14  to selectively move between its full up and full down positions as desired. Optionally, a sensor(s) monitors rotation of the motor output shaft  78  and power band of the motor  30  is measured to ensure that proper power requirements are being used to permit the closure member  14  to be moved from the full down position to the full up position or any intermediate position desire by the operator and to prevent pinching of a human limb or appendage. 
       FIG. 14  illustrates a closure mechanism  102  according to a second embodiment of the present invention which is substantially identical to the first embodiment described above in detail except that it is adapted for moving a generally planar closure member  14  along a generally straight path. This illustrates that the closure mechanism  10 ,  104  of the present invention can be utilized with closure members  14  having other forms. 
     From the foregoing disclosure and detailed description of certain preferred embodiments, it is also apparent that various modifications, additions and other alternative embodiments are possible without departing from the true scope and spirit of the present invention. The embodiments discussed were chosen and described to provide the best illustration of the principles of the present invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present invention as determined by the appended claims when interpreted in accordance with the benefit to which they are fairly, legally, and equitably entitled.