LOW COST AND LIGHT WEIGHT HANDLE SHAFT FOR WINDOW

REGULATOR ASSEMBLY

BACKGROUND Technical Field

[0001] The embodiments herein generally relate to a handle shaft of a window regulator assembly of an automotive vehicle, and, more particularly, to a handle shaft with a mould that includes a plastic material.

Description of the Related Art

[0002] Automotive vehicles have windows that are opened and closed via window regulator assemblies. These windows are either manually operated or power controlled. Various arrangements of an automotive window regulator and drive arrangements have been developed over the years. These arrangements vary widely from complex lever arm and gear configurations, rack and pinion type drive arrangements, to metal shaft drive arrangements. However, most of these arrangements employ numerous metal parts which may differ for each type of vehicle and thus lead to increasing their cost.

[0003] An automotive window regulator includes a handle shaft which is typically I made up of metal such as steel, zinc, etc. During rotation of a handle of the automotive window regulator, a load is developed on the handle shaft. In order to withstand high stress and the load that develops on the handle shaft, the handle shaft is made of metal. Even though a metal handle shaft offers high resistance towards the load, and is not easily breakable, still it has various disadvantages. One such disadvantage is that usage of zinc material in the handle shaft causes creation of zinc flake over a period of time due to high load. This creates a structural damage to the handle shaft. Also, usage of a metal handle shaft increases the weight of the vehicle, which in turn has an adverse effect on the fuel economy of the vehicle and is expensive too. Accordingly, there remains a need for a window regulator assembly includes a handle shaft that can withstand a high load, has less weight, and is cost effective.

SUMMARY

[0004] In view of the foregoing, an embodiment herein provides a window regulator assembly for raising and lowering a window of a vehicle includes a handle shaft. The handle shaft includes (a) an insert includes a proximal end portion, a mid-portion, and a distal end portion. The proximal end portion is configured to drivingly engage a pinion of the window regulator assembly. The handle shaft further includes (b) a mould that is configured to rotatably support the mid-portion of the insert. The mould includes an outer cylindrical portion proximal to the mould, an inner cylindrical portion, and an undercut portion distal to the mould. The undercut portion includes plastic and is configured to attach to a handle of the window regulator assembly. The undercut portion that includes the plastic may be made up of Nylon 6 60% glass filled. The undercut portion that includes the plastic may be made up of Nylon 6.6 30% glass filled. A diameter of the proximal end portion and the distal end portion of the insert may be 5 +/- 0.2mm. A diameter of the undercut portion may be 8.5 +/-0.2mm, and it may withstand a load that may range between 19 Nm to 21 Nm.

[0005] In another embodiment, a handle shaft for a window regulator is provided. The handle shaft includes (a) an insert includes a proximal end portion, a mid-portion, and a distal end portion. The proximal end portion is configured to drivingly engage a pinion of the window regulator assembly. The handle shaft further includes (b) a mould that is configured to rotatably support the mid-portion of the insert. The mould includes an outer cylindrical portion proximal to the mould, an inner cylindrical portion, and an undercut portion distal to the mould. The inner cylindrical portion includes plastic. The plastic may be made up of Nylon 6 60% glass filled.

[0006] In yet another embodiment, a handle shaft for a window regulator is provided. The handle shaft includes (a) an insert includes a proximal end portion, a mid-portion, and a distal end portion. The proximal end portion is configured to drivingly engage a pinion of the window regulator assembly. The handle shaft further includes (b) a mould that is configured to rotatably support the mid-portion of the insert. The mould includes an outer cylindrical portion proximal to the mould, an inner cylindrical portion, and an undercut portion distal to the mould. The outer cylindrical portion includes plastic and is configured to accommodate the insert. The plastic may be made up of Nylon 6 60% glass filled.

[0007] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:

[0009] FIG. 1 illustrates a perspective view of a window regulator assembly for raising and lowering a window of a vehicle according to an embodiment herein;

[0010] FIG. 2 illustrates a perspective view of the handle shaft of the window regulator assembly of FIG. 1 according to an embodiment herein; i

[0011] FIG. 3 illustrates a perspective view of a drive mechanism of the window regulator assembly of FIG. 1 according to an embodiment herein;

[0012] FIG. 4 illustrates a perspective view of the handle shaft with the undercut portion of FIG. 2 that attaches to a handle of the window regulator assembly according to an embodiment herein;

[0013] FIG. 5 is a table view illustrating a test that was conducted for two different compositions of plastic material that includes a load, up to which the undercut portion of FIG. 2 that is made up of the plastic material withstands, for two different diameters of the circular proximal end portion and the splined distal end portion of the insert of FIG. 2, and at a temperature of 80°C in different time intervals according to an embodiment herein; and

[0014] FIG. 6 is a flow chart illustrating a working mechanism of the window regulator assembly 100 of FIG. 1 according to an embodiment herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0015] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0016] As mentioned, there remains a need for a window regulator assembly that includes a handle shaft that can withstand a high load, has less weight, and is cost effective. The embodiments herein achieve this by providing a handle shaft that is made up of plastic which can withstand a higher load. Referring now to the drawings, and more particularly to FIGS. 1 through FIG. 6, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.

[0017] FIG. 1 illustrates a perspective view of a window regulator assembly 100 for raising and lowering a window of a vehicle according to an embodiment herein. The window regulator assembly 100 includes a centre plate 102, a handle shaft 104, a gear sector 106, a main arm 108, a sub arm 110, a first channel 112, a second channel 114, a roller 116, a fastener 118, and a cup 120. The centre plate 102 houses the handle shaft 104, and is fixed to the main arm 108 of the window regulator assembly using the fastener 118. The handle shaft 104 is rotatable and supported upon the centre plate 102 by the cup 120. A driving mechanism of the window regulator assembly is secured to an end thereof in meshing and a driving engagement with teeth is provided around a periphery of the gear sector 106 which is welded to the main arm 108. The main arm 108 is connected to the first channel 112 by the roller 116. The roller 116 slides and is riveted to the main arm 108 through the fastener 118. This allows converting the rotary movement of a handle of the window regulator assembly to linear movement of the window. A proximal end of the sub arm 110 is attached to the first channel 112, whereas a distal end of the sub arm 110 is attached to the second channel 114. The second channel 114 is used to raise and/or lower the window of the vehicle along with the main arm 108, and the first channel 112.

[0018] FIG. 2 illustrates a perspective view of the handle shaft 104 of the window regulator assembly 100 of FIG. 1 according to an embodiment herein. The handle shaft 104 includes an insert 202, and a mould 204. The insert 202 is fitted into the mould 204. The handle shaft 104 houses the handle and transmits motion from the handle to a drive assembly to raise and/or lower a window of a vehicle. The insert 202 includes a circular proximal end portion 206, a cylindrical mid-portion 208, and a splined distal end portion 210. In one embodiment, the insert 202 is made of steel or a zinc alloy. The mould 204 includes an outer cylindrical portion 212 proximal to the mould, an inner cylindrical portion 214, and an undercut potion 216 distal to the mould. The circular proximal end portion 206 of the insert is adapted and configured to drivingly engage an opening provided in a pinion (not shown in FIG. 2) of the window regulator assembly 100.

[0019] The cylindrical mid-portion 208 is adapted and configured to be rotatably supported in an opening provided in the mould 204. The splined distal end portion 210 is accommodated by the undercut portion 216 which is adapted and configured to receive a handle (not shown) for rotatably driving a drive assembly of the window regulator assembly. In one embodiment, the insert 202 and the mould 204 are designed such that they increase torque of the handle through the handle shaft 104 of FIG. 1.

[0020] In one embodiment, a diameter of the circular proximal end portion 206 and the splined distal end portion 210 are same. In another embodiment, a diameter of the circular proximal end portion 206 and the splined distal end portion 210 are different. In one embodiment, the diameter of the circular proximal end portion 206 and the diameter of the splined distal end portion 210 are both 5.0 mm+/-0.2mm. In one embodiment, a diameter of the undercut portion is 8.5 mm.+/-0.2mm

[0021] FIG. 3 illustrates a perspective view of a drive mechanism 300 of the window regulator assembly 100 of FIG. 1 according to an embodiment. The perspective view of the I drive mechanism 300 includes the cup 120, the insert 202, the mould 204, a pinion 302, a clutch 304, and a torsion spring 306. The pinion 302 is engaged with a slot of the clutch 304. The pinion 302 has an opening which receives the circular proximal end portion 206 of the insert 202. The handle shaft 104 has the splined distal end portion 210 which extends through and is rotatably supported on the cup 120.

[0022] A torsion spring 306 is positioned in a gap between an outer periphery of the mould 204 and an inner periphery of the cup 120. The torsion spring 306 has one end engaged with the splined distal end portion 210 of the insert 202 and its other end frictionally engaged with the cup 120. The torsion spring 306 acts as a one-way clutch allowing the clutch 304 and the handle shaft 104 to be rotated by the handle (not shown in FIG. 3). The torsion spring 306 further prevents the clutch 304 and the handle shaft 104 from being rotated when a force is applied to a window in a downward direction. The handle is fixed to the undercut portion 216 through the cup 120 so that by rotating the handle in a counter¬clockwise direction, the clutch 304 and the handle shaft 104 are rotated to raise a window. Also, when the handle is rotated in the counter-clockwise direction, the torsion spring 306 unwinds or stretches and assists rotational torque of the handle through the handle shaft 104 and the clutch 304.

[0023] FIG. 4 illustrates a perspective view of the handle shaft 104 with the undercut portion 216 of FIG. 2 that attaches to a handle 402 of the window regulator assembly 100 according to an embodiment herein. The handle 402 fits in a groove 404 in the undercut portion 216 of the mould 204 through a circlip 406. The circlip 406 does not allow the handle 402 to pull out from the groove 404. When a user rotates the handle 402 to open or close a window of a vehicle, and/or when the window hits the top of the vehicle frame, a load (e.g., torque) is developed in the undercut portion 216. The undercut portion 216 is designed using a plastic material in such a way that it can withstand the load. In one embodiment, the plastic material is Nylon 6 60% glass filled. In one embodiment, the entire mould 204 is made up of plastic. In another embodiment, the outer cylindrical portion 212 of the mould is made up of plastic, and the inner cylindrical portion 214 and the undercut portion 216 is made up of metal. In yet another embodiment, the inner cylindrical portion is made up of plastic, and the outer cylindrical portion 212 and the undercut portion 216 is made up of metal. In a further embodiment, the undercut portion 216 is made up of plastic, and the outer cylindrical portion 212 and the inner cylindrical portion 214 is made up of metal. The plastic material Nylon 6 60% glass filled can withstand the load in a range of 19 to 21 Nm even at higher temperatures, whereas a typical requirement sufficient for most vehicles is for the undercut portion to be capable of withstanding 17.6 Nm at a normal temperature. In one embodiment, the plastic material Nylon 6 60% glass filled can also withstand a minimal load (e.g., 0Nmtol9Nm).

[0024] FIG. 5 is a table view 500 illustrating a test that was conducted for two different compositions of plastic material that includes a load 502, up to which the undercut portion 216 of FIG. 2 that is made up of plastic material withstands, for two different diameters of the circular proximal end portion 206 and the splined distal end portion 210 of the insert 202, and at a temperature of 80°C in different time intervals according to an embodiment herein. In one embodiment, the mould 204 with a diameter of the undercut portion 216 ranging between 8.5 mm +/- 0.2mm. The insert 202 with a diameter of the circular proximal end portion 206 and the splinded distal end portion 210 is 4.5 mm. The undercut portion 216 includes the plastic material of Nylon 6.6 30% glass filled. The maximum loads which the undercut portion 216 withstands are 15, 12, 10, and 9 Nm at a room temperature, 80°C for 8 hours, 80°C for 24 hours, and 80°C for 30 hours respectively.

Similarly, In another embodiment, the mould 204 with a diameter of the undercut portion 216 ranging between 8.5 mm+/- 0.2mm. The insert 202 with a diameter of the circular proximal end portion 206 and the splinded distal end portion 210 is 5.0 mm. The undercut portion 216 includes the plastic material of Nylon 6.6 30% glass filled. The maximum loads which the undercut portion 216 withstands are 18,15,14, and 13 Nm at a room temperature, 80°C for 8 hours, 80°C for 24 hours, and 80°C for 30 hours respectively. This data shows that increasing the diameter of the circular proximal end portion 206 and the splinded distal end portion 210 increases the load 502 withstand capability in the undercut portion 216. However, when the diameter is increased further for a range, the handle 402 can be easily pulled out from the undercut portion 216. Therefore, the diameter of the circular proximal end portion 206 and the splinded distal end portion 210 have to make the undercut portion 216 to withstand the load, in addition to not allowing the handle 402 to pull out from the undercut portion 216.

[0025] From the table, in one embodiment, the mould 204 with a diameter of the undercut portion 216 ranges between 8.5 mm +/- 0.2mm. The insert 202 with a diameter of the circular proximal end portion 206 and the splinded distal end portion 210 is 5.0 mm. The undercut portion 216 includes the plastic material of Nylon 6 60% glass filled. The undercut portion 216 withstands a maximum of 21 Nm even at a higher temperature, and this diameter does not allow the handle 402 to pull out from the groove 404. Thus, the plastic material of Nylon 6 60% glass filled provides more torsion withstand capability to the mould 204.

[0026] FIG. 6 is a flow chart 600 illustrating a working mechanism of the window regulator assembly 100 of FIG. 1 according to an embodiment herein. In step 602, the handle shaft 104 is rotated using the handle 402 of the window regulator assembly 100. In step 604, the handle shaft 104 transfers a rotary movement to the clutch 304, and the pinion 302. In step 606, the pinion 302 that is connected to the gear sector 106 that are welded to the main arm 108 of the window regulator assembly 100. In step 608, the main arm 108 and the sub arm 110 transfers the rotary movement of the pinion 302 to a vertical or a linear movement of a window. In step 610, the first channel 112 that is connected to the main arm 108 is used to perform raising and/or lowering the window.

[0027] In one embodiment, the weight of the handle shaft 104 is reduced by two times when compared to a metal handle shaft, which in turn reduces the weight of a vehicle, and thus improves fuel economy of the vehicle. Also, the plastic material by which the handle shaft 104 is made provides a high load withstand capability. The handle shaft 104 transmits a motion from the 402 handle to the drive mechanism 300. The design of the insert 202 and the material of mould 204 provide required stability, grip, and torsion strength to raise and/or lower a window. Further, cost of the handle shaft 104 of the window regulator assembly 100 is reduced by two to three folds when compared to the metal handle shaft.

[0028] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications • should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the invention.

CLAIMS

What is claimed is:

1. A window regulator assembly for raising and lowering a window of a vehicle, said window regulator assembly comprising a handle shaft, wherein said handle shaft comprises:

(a) an insert comprising a proximal end portion, a mid-portion, and a distal end portion, wherein said proximal end portion is configured to drivingly engage a pinion of said window regulator assembly; and

(b) a mould that is configured to rotatably support said mid-portion of said insert, wherein said mould comprises an outer cylindrical portion proximal to said mould, an inner cylindrical portion, and an undercut portion distal to said mould, wherein said undercut portion comprises plastic and is configured to attach to a handle of said window regulator assembly.

2. The window regulator assembly of claim 1, wherein said plastic is Nylon 6 60% glass filled.

3. The window regulator assembly of claim 1, wherein said plastic is Nylon 6.6 30% glass filled.

4. The window regulator assembly of claim 1, wherein a diameter of said proximal end portion and said distal end portion of said insert ranges between 4.8 mm to 5.2 mm.

5. The window regulator assembly of claim 1, wherein a diameter of said undercut portion ranges between 8.3 mm to 8.7 mm.

6. The window regulator assembly of claim 5, wherein said undercut portion of said mould withstands a load that ranges between 19 nm to 21 Nm.

7. A handle shaft for a window regulator assembly, wherein said handle shaft comprises:

(a) an insert comprising a proximal end portion, a mid-portion, and a distal end portion, wherein said proximal end is configured to drivingly engage a pinion of said window regulator assembly; and

(b) a mould that is configured to rotatably support said mid-portion of said insert, wherein said mould comprises an outer cylindrical portion proximal to said mould, an inner cylindrical portion, and an undercut portion distal to said mould, wherein said inner cylindrical portion comprises plastic.

8. The window regulator assembly of claim 7, wherein said plastic is Nylon 6 60% glass filled.

9. A handle shaft for a window regulator assembly, wherein said handle shaft comprises:

(a) an insert comprising a proximal end portion, a mid-portion, and a distal end portion, wherein said proximal end is configured to drivingly engage a pinion of said window regulator assembly; and

(b) a mould that is configured to rotatably support said mid-portion of said insert, wherein said mould comprises an outer cylindrical portion proximal to said mould, an inner cylindrical portion, and an undercut portion distal to said mould, wherein said outer cylindrical portion comprises plastic and is configured to accommodate said insert.

10. The window regulator assembly of claim 9, wherein said plastic is Nylon 6 60% glass filled.