Patent Publication Number: US-2022227334-A1

Title: Automotive window regulator slide block repair kit and method of using the same

Description:
BACKGROUND OF THE INVENTION 
     Conventional electrically operated windows are systems designed to raise and lower the vehicles windows via devise called an electric window regulator. Typically, there is an electric window regulator for each door with an associated switch. Often, the driver&#39;s door has a set of switches that allows the driver to operate the power windows in both front doors. Manually operated window regulators are also used, and the task of lowering and raising of the window is accomplished by rotating the corresponding window regulator crank handle. Thus, it is generally a requirement that the raising and lowering mechanisms of the window regulators are installer inside of the in the door structure as well. 
     In a traditional single arm power window regulator, the window&#39;s lifting mechanism consists of a linkage designed to lift the window while at the same time keeping the window horizontally leveled. 
     An electric motor is attached to a worm gear, a spur gear, and the segment gear of the linkage arm to create gear reduction sufficient to generate enough torque to move the window. The window regulator is attached by rivets or bolted to the door frame structure. Window regulators linkage arm is fitted with plastic slide block that is riveted to it at one end. Slide block is inserted into a slide block guide channel that is connected to the bottom of the window glass during the door assembly process. 
     The radial movement of the window regulators arm transfers into vertical movement of the door window glass through the slide block that moves within and along the length of the slide guide channel at the bottom of the window glass. 
     The electric motor of the window regulator is connected to a reversable switch. Activating the electric switch causes supply of the current that causes the motor to rotate the worm gear. Reversing the current flow causes the electric motor to rotate in opposite directions. The worm gear is meshed with the spur gears. When the worm gear rotates, the spur gears turn in conjunction with the worm gear. 
     The linkage arm has a segment gear at one end with teeth that are meshed with the spur gear. Thus, the segment gear of the linkage is permanently in mechanical contact with the worm gear. This prevents the linkage arm from the movement and allows the movement when the electric motor is activated. The linkage arm is attached to the swivels point pin that of the window regulator motor bracket. Position of the pin provides constant contact of the segmented gear of the linkage. 
     When the spur gear turns, its teeth engage and disengage with successive linkage segmented gear teeth. This causing the end of the segment gear to move depending upon the direction of rotation of the spur gear. As the segmented end of the linkage moves, the linkage rotates about the pin and the linkage arm end with the slide block moves in opposition to the geared end. Because the linkage arm end is disposed in the window slide guide via slide block, the movement of the linkage arm causes the end to move along the groove of the slide guide and the window to raise or lower. 
     When the window goes up or down, the drive motor and regulator work in sync always. 
     Through the course of the vehicle use, the components of the window regulator mechanisms begin working with greater effort that originally designed due to its age, and sometimes the lack of maintenance is a well-known contributing factor. Often it can be because the surfaces of the door window glass rubberized insulation gaskets drying out and having increased coefficients of friction. 
     At times, the window class become stuck or harder to move, due in part to a variety of factors such as ice buildup, and exposure to dust, dirt. This can cause the window regulator failure. 
     It is a common failure of the window regulator, when slide guide block that is made of the plastic material becomes shattered, causing window regulator arm to disengage from the slide guide channel at the bottom of the window glass, and window drop inside of the door frame. 
     As a part of the repair procedure, the damaged component should be replaced with a new part. However, due to the original design of the window regulator, since the plastic slide block is permanently attached by a rivet to the arm, the replacement part only available from the supplier in the form of complete window regulator assembly. 
     Since the window regulator is located within the door the structure, the repair procedure calls for removal of the entire window regulator assembly form the door and replacing it with the new one. 
     Being able to replace only the commonly damaged plastic slide block of the window regulator with an upgraded and re-designed part and being able to conduct the repairs without removing the entire assembly from the vehicle would make the repair much easier and more economical. 
     Thus, there is a need for a service kit for the window regulator repair, further, it is advantageous for this to be done without removing the window regulator from the vehicle to conduct the repair. 
     For all the above reasons, there is a need for a method for inexpensively repairing of the window regulator that allows the user to replace only the damaged slide block, leaving the original window regulator in place. The replacement slide block can use stronger materials than the original slide block, be configured with the same or a different design. The present invention attempts to satisfy these needs. 
     SUMMARY OF THE INVENTION 
     The present invention is a method for replacing of the damaged slide block of a window regulator used for operating of the door windows in the w 901, 902 and 903 series Mercedes Benz Sprinter and Dodge Sprinter vans, built between 1995 and 2006, Mercedes Benz Sprinter vans built between 1995-2002, Dodge Sprinter vans 2500, 3500 built between 2002 and 2006, Freightliner Sprinter vans 2500, 3500 built between 2002 and 2006 without removing the window regulator from the vehicle. 
     Often, the plastic slide block of the window regulator on these vehicles, which has the primary purpose of providing a sliding joint between the lifting arm of a window regulator and the slide guide channel of the window glass, becomes damaged over time due to the stress placed on slide block. The user must then take the vehicle to a dealer, independent repair facility, or do the work himself and have the window regulator slide block replaced, which includes replacement of the entire window regulator assembly, at a significant cost. 
     Instead of absorbing the cost of replacing of the entire window regulator assembly, because of a damaged slide block, the present invention provides for the replacement of the slide block kit, leaving the window regulator assembly in place, without removing the window regulator assembly from the door of the vehicle. In doing so, the replacement slide block for a window regulator will be made from a stronger material to reduce the chance of further damage. Also, the replacement slide block for window regulator can be made in the form of a repair kit that will include mounting hardware for the installation. 
     It is an objective of the present invention to provide a replacement slide block of a window regulator for a door window in a 901, 902 and 903 series Mercedes Benz Sprinter and Dodge Sprinter vans, built between 1995 and 2006, Mercedes Benz Sprinter vans built between 1995-2002, Dodge Sprinter vans 2500, 3500 built between 2002 and 2006, Freightliner Sprinter vans 2500, 3500 built between 2002 and 2006. 
     It is another objective of the present invention to provide a replacement slide block of a window regulator for a door window in a w 901, 902 and 903 series Mercedes Benz Sprinter and Dodge Sprinter vans, built between 1995 and 2006, Mercedes Benz Sprinter vans built between 1995-2002, Dodge Sprinter vans 2500, 3500 built between 2002 and 2006, Freightliner Sprinter vans 2500, 3500 built between 2002 and 2006 of the similar design that was damaged due to wear-and-tear or from stress placed on the point where the slide block is attached to the window regulator arm where the slide block is connected to the slide block guide. 
     It is another objective of the present invention to provide for the replacement slide block of the window regulator and the attachment kit for a damaged slide block using a different type of the material than the original. 
     It is another objective of the present invention to provide for the replacement of a damaged slide block of the window regulator using a differently designed mounting hardware than the original. 
     It is another objective of the present invention to provide for the replacement of a damaged slide block of the window regulator and all of the mounting hardware necessary for repair of an existing original window regulator. 
     While the invention is described herein with relation to certain embodiments and applications, those with skill in this art will recognize changes, modifications, alterations and the like which still come within the spirit of the inventive concept, and such are intended to be included within the scope of the invention, as expressed in the drawings, description and claims disclosed herein. 
    
    
     
       DESCRIPTIONS OF THE FIGURES 
       The invention can be better understood by relating the following detailed description of certain preferred embodiments, reference is being made to the accompanying drawings in which: 
         FIG. 1  is a picture of a front plain view of single arm window regulator assembly according with the prior art. 
         FIG. 2  is a picture of a front plain partial view of window regulator with the linkage arm with the slide block according with the prior art. 
         FIG. 3  is a picture of a front plain partial view of window regulator with the linkage arm with the damaged slide block according with the prior art. 
         FIG. 4  is a picture of a perspective view of both sides of a replacement slide block for a window regulator prior to installation according to one embodiment of the present invention. 
         FIG. 5  is a picture of a perspective view of a mounting bolt for the replacement slide block for a window regulator prior to installation according to one embodiment of the present invention. 
         FIG. 6  is a picture of a perspective view of a locking nut for the mounting bolt for the replacement slide block for a window regulator prior to installation according to one embodiment of the present invention. 
         FIG. 7  is a picture of a perspective view of the slide block kit that includes replacement slide block, mounting bolt, and the locking nut for a window regulator prior to installation according to one embodiment of the present invention. 
         FIG. 8  is a picture of a front plain partial view of the slide block kit that includes replacement slide block, mounting bolt, and the locking nut for a window regulator after the installation according to one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention is a method for replacing the damaged slide block of a window regulator used for lowering and raising the door windows in a w 901, 902 and 903 series Mercedes Benz Sprinter and Dodge Sprinter vans, built between 1995 and 2006, Mercedes Benz Sprinter vans built between 1995-2002, Dodge Sprinter vans 2500, 3500 built between 2002 and 2006, Freightliner Sprinter vans 2500, 3500 built between 2002 and 2006. 
     The method of the present invention provides for a replacement slide block of a window regulator assembly that may have been damaged due to wear-and-tear from daily use or broken when some other accidental condition occurred. In the preferred embodiment of the present invention, the window regulator mechanism of the window regulator has not been damaged, only the slide block of a window regulator device has been damaged. 
     The method of the present invention includes removing of the damaged portion of the slide block and its mounting hardware from the window regulator assembly without removing the window regulator from the vehicle and installing a replacement slide block kit that will allow for the same or improved functionality as the original slide block. That functionality may include lowering and raising the window of the vehicle and providing security by preventing window from uncontrolled down movement, among other functionalities. 
     Additionally, the present invention provides for the replacement of the slide block of a window regulator that was damaged with a slide block kit that is made from stronger material. In an alternative embodiment, the method of the present invention provides for the replacement of a damaged slide block and mounting hardware necessary for the window regulator functionality described herein. 
       FIG. 1  illustrates front plain view of single arm window regulator assembly  10 , as understood by one having ordinary skill in the art. The single arm window regulator assemblies are usually made throughout of stamped steel for strength and is configured with a regulator arm  11 , segmented gear section  12 , and a linkage arm section  13 . The slide block  14  is mounted on a steel shaft to provide a swivel point (not shown) and permanently attached by the rivet  15  at the end of the linkage arm section  13 . The slide block  14  of the window regulator  10  is further engaged with the slide guide rail track  16  of the window glass assembly  17 . The window regulator assembly  10  also fitted with a spur gear  18  and electric motor  19  with a worm gear (not shown) and attached to the motor bracket  20 . Linkage arm  11  is also attached to the motor bracket  20  at the swivel point  21 . 
     Most vehicles today are fitted with electrically or manually operated window regulators. Since the door window regulator continued to be necessary to lower or rase the window, the w 901, 902 and 903 series Mercedes Benz Sprinter and Dodge Sprinter vans, built between 1995 and 2006, Mercedes Benz Sprinter vans built between 1995-2002, Dodge Sprinter vans 2500, 3500 built between 2002 and 2006, Freightliner Sprinter vans 2500, 3500 built between 2002 and 2006 were fitted with a single arm window regulator. 
     During the production and the assembly of the window regulators for the forementioned series vehicles, —stamped steel and injection molded plastic parts were utilized. One of the injection-molded plastic components is incorporated into a window regulator assembly, is a slide guide block  14  of the drawing. 
     This part is designed to create a contact point between the door window regulator and the window glass assembly. While permanently attached to the end of the window regulator assembly arm, slide block  14  is designated to move along the length of the slide guide rail track  16  at the bottom of a window glass  17  during the operation. Incorporated into a stamped steel construction of the window regulator  10 , a plastic slide block component  14 , can be viewed as a vulnerable part. In many cases the plastic slide block  14 , became damaged, causing a failure of the assembly  10 . 
       FIG. 2  illustrates front plain partial view of window regulator  10 , containing linkage arm section  13 , slide block  14 , slide block mounting pin rivet head  15 , and the slide block guide rail  16 . In this illustration, the slide block  14 , is permanently attached to the linkage arm section  13  of the window regulator assembly  10 . Further the configuration of the mounting pin with the rivet head  15  includes the shaft portion (not visible), that allows the slide block  14  to rotate about its axis. The slide block  14  is inserted into a guide rail track  16  that is attached to the bottom of the window glass  17 . It is also understood that the slide block  14  can move along the inner track of the slide guide rail track  16 , while rotated about the shaft of the slide block attachment rivet  15 . 
     The slide block  14  can move along the length of the track of the slide guide rail  16  without leaving the track for the reason of being guided by the overlapping edges  22  of the guide rail. The length of the slide guide rail track  16  prevents the slide block  14  from leaving the track at ether ends. Further, the slide block  14  creates positive connection between the window regulator assembly  10  and the slide guide rail track  16  at the bottom of the window glass  17 . 
       FIG. 3  illustrates front plain partial view of the of window regulator  10 , containing linkage arm  13 , damaged slide block  14  that is split into two damaged sections  23  and  24 , slide block attachment rivet  15 , and the slide block guide rail track  16 . In this embodiment, the slide block  14 , is split by the pressure from the shaft of the mounting pin with the rivet head  15  of the linkage arm  13  of the window regulator assembly  10  causing failure of the window regulator  10 . As described herein, this condition is possible through normal wear-and-tear, or through an accident, for the slide block  14  to become damaged. In those instances, a linkage arm  13  of the window regulator will no longer relate to the window glass and will not be able to move or to secure the window in desired position. 
     In this event, a new replacement slide block can be used to replace the damaged one to provide the same functionality. Further, the replacement slide block can be manufactured in stronger material and different designs and still provide the same functionality. Further, the new replacement slide block can be offered in the form of a repair kit. 
       FIG. 4  illustrates a perspective view of both sides of a replacement slide block  25 . The slide block may be elongated, having a length longer than the width. The long sides may include half-round profiles  30 . 
     The distance between the edges of the half round profiles  30  may be less than the inside height of the slide guide rail track  16 . 
     The distance between the front side  32  of the slide block  25  and the back side  33  may be less than the inside width of the slide guide rail track  16 . 
     The front side  32  of the slide block  25  and the back side  33  of the slide block  25  may include two pocket  28  at either short end. 
     The depth of the pockets  28  may be less than one third of the distance between the front and back sides of the slide block  25 . 
     The length of the pockets  28  may be less than one fourth of the distance between the short edges of the slide block  25 . 
     The width of the pockets  28  may be less than one half of the distance between the long edges of the slide block  25 . 
     The back side  33  of the slide block  25  may include cylindrical section  29  that is shorter than the length of cylindrical section  37  of the mounting bolt  35 . 
     The cylindrical section  29  may include two flat section  34  that are parallel to each other. 
     The distance between the flat sections  34  may be less than the distance between the overlapping edges  22  of the slide guide rail track  16 . 
     The flat sections  34  may be parallel to the long sides of the of the profiles  30  of the slide block  25 . 
     The cylindrical section  29  may be placed in the relative center of the back side  33  of the slide block  25 . 
     The cylindrical section  29  may include the aperture  26  located in the center. The diameter of the aperture  26  may be larger than the diameter of the cylindrical portion  37  of the mounting bolt  35 . 
     The front side  32  of the slide block  25  may include counterbore to enlarge the aperture  26 . The diameter of the counterbore  31  may be larger than the diameter of the shoulder portion  36  of the mounting bolt  35 . The depth of the counterbore  31  may be deeper than the height of the shoulder portion  36  of the mounting bolt  35 . The distance between front side  32  of the slide block  25  and the bottom edge  27  of the counterbore  31  may be less than one half of the thickness of the slide block  25 . 
       FIG. 5  Illustrates a perspective view of the mounting bolt  35 . The bolt may be elongated, having a length longer than the width. The bolt may include a shoulder portion  36  that is smaller in diameter than the diameter of the counterbore  31  of the slide block  25 . 
     The shoulder section  36  may serve as a stop, when bot is inserted into the aperture  26  of the slide block  25 . The shoulder section  36  may rest against the bottom of the counterbore  27  of the slide block  25 . The length of the shoulder section  36  may be shorter than the depth of the counterbore  31  of the slide block  25 . 
     The bolt may include a cylindrical section  37 , that may be smaller in diameter than the shoulder section  36 . 
     The cylindrical section  37 , may be longer than the cylindrical section  29  of the slide block  25 . 
     The cylindrical section  37  may be smaller in diameter than the aperture  26  of the slide block  25 . 
     The cylindrical section  37  may serve as the bearing for the slide block  25  when installed into the aperture  26 . 
     The bolt  35  may include neck section  38  that may be smaller in diameter than the section  37 . 
     The bolt  35  may include the threaded portion  39  which thread diameter may be smaller than diameter of the section  37 , and smaller than the size of the rivet hole in linkage arm portion  13  of the window regulator assembly  10  shown in the  FIG. 1  illustration. 
     The length of the threaded portion  39  of the of the bolt  35  may exceed the total height of the locking nut  42  illustrated in  FIG. 6  by at least two times. 
     The threaded portion  39  is followed by cylindrical section  40  that may be smaller in diameter than the inner diameter of the nylon lock washer in section  43  of the locking nut  42  illustrated in  FIG. 6 . 
     The cylindrical section  40  may include two notches  41  formed on its outer periphery. The notches may be placed opposite to each other and serve as a rest point for the retaining devise during the assembly process. 
     The length of the cylindrical section  40  may be 4 times longer than the crimped section  44  of the locking nut  42  illustrated in  FIG. 6 . 
       FIG. 7  illustrates a perspective view of the slide block  25 , mounting bolt  35 , and the locking nut  42  of the preferred embodiment of the present invention. 
       FIG. 8  illustrates front plain partial view of the of window regulator containing slide block  25 , mounting bolt  35 , and the locking nut  42  that are assembled into the window regulator assembly  10 , where the mounting bolt  35 , is installed the hole of the slide block  25 , inserted into the slide block guide rail track  16 , protruded through the rivet hole at the end of the linkage arm  13  and secured with the locking nut  42  as outlined in the preferred embodiment of the present invention 
     The method of the present invention includes gaining access to the window regulator within the structure of the vehicle door, by means of the removal of the interior decorative door panel (not shown), leaving the window regulator assembly  10  attached to the door structure, locating access opening within the door frame for the window regulator arm slide block mounting pin rivet head  15 , aligning the end of the window regulators linkage arm  13  of the window regulator assembly against the access opening (not shown) by operating window regulator by means of power switch or manually, taking measures to temporarily secure the window glass  17  in the desired position to prevent vertical movement of the same by means of applying adhesive tape to window glass and the door window frame (not shown), locating and grinding off the slide block mounting pin rivet head  15  of slide block mounting pin using suitable tool, removing remaining portion of the mounting shaft pin (not shown) from the window regulators linkage arm  13 , exposing and preparing using suitable tools an existing hole to accept a threaded portion  39  of the replacement bolt  35 . Preparing the replacement slide block  25  for installation by inserting lubricated replacement bolt  35  into a hole on the front side  32  of the slide block  25 . Locating the end of the slide block guide rail  16  within the door structure. Installing lubricated replacement block  25  by sliding it into the guide rail track  16  while keeping the cylindrical shoulder portion  36  of the mounting bolt  35  even with the surface  32  of the slide block  25  and facing the back of the guide rail track  16 , aligning the threaded portion  39  of the slide block mounting bolt  35  against the exposed prepared hole of the window regulators linkage arm  13  by operating the window regulator assembly or moving the slide block accordingly, protruding the threaded portion  39  of the mounting bolt  35  through the mounting hole of the regulators linkage arm  13 . Installing the locking nut  42  onto cylindrical section  40  of the mounting bolt  35 . Rotating the nut  42  by hand to engage with the threaded portion  39  all the way until resistance of the nylon lock washer in section  43  is observed. Attaching suitable tool against exposed sections  41  of the mounting bolt  35 . Driving the nut  42  with suitable tool to make tight connection. removing adhesive tape used to secure the window glass in the desired position to allow vertical movement of the glass within the frame; testing for functionality by operating window regulator manually or by power switch as equipped; installing the door decorative panel in its place. 
     Other methods of repairing damaged or, updating functional non-damaged window regulator assembly  10  with the replacement slide block kit include: removing the window regulator from the door structure, use manually or power operated tools and equipment or any other means to securely repair window regulators with repair kit provided. Further, in replacing the window regulators slide block, the present invention also contemplates replacing some or all the window regulator components, if there has been damage observed. 
     Now with the use of the replacement slide block kit, the functionality of the window regulator assembly  10  has been restored at a significant savings to the vehicle owner. 
     Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiment described herein.