Tensioner for a vehicle window lifter

Abstract

A tensioner (41) for a window lifter (16) for raising and lowering a window (14) of a vehicle (10), the tensioner (41) comprising: a first tensioner support (50); a second tensioner support (56); a spring (52) disposed between the first tensioner support (50) and the second tensioner support (56); and an adjustment sleeve (54) configured to engage a feature of the first tensioner support (50) when the second tensioner support (56) is moved away from the first tensioner support (50) due to the biasing force of the spring (52).

Description

Technical Field

[0001] Exemplary embodiments relate to the field of vehicles, and more particularly to a tensioner for a window regulator. Background Art

[0002] Passenger vehicles typically have windows around the passenger compartment. The windows on the doors can be designed to be electrically raised and lowered by an operator. The operator can typically be the driver or a passenger using an interior switch. The physical raising and lowering of the window is accomplished by an electromechanical device called a window regulator.

[0003] The window regulator includes a drive unit (motor) connected to a drive means (such as a cable or belt) that transmits driving force to the window regulator. The window can be driven by a slider that can move along a track or guide rail under the action of the cable. The cable can be divided into a lower cable and an upper cable that are wound around a drum driven by the motor in opposite directions.

[0004] The tension force in one or more cables in the window regulator must be effectively controlled. Slack in one or more cables results in inaccurate operation of the window regulator and inaccurate positioning of the slider relative to the drum around which the cable is wound. On the other hand, excessive cable tension force can lead to inefficiency and premature wear of the window regulator components.

[0005] The operating accuracy of the window regulator is important, especially for window regulators used in frameless doors. In a frameless door, when the door is fully closed, the top edge of the window engages with the roof seal.

[0006] The components of the window adjustment device gradually age, which can cause the cable to elongate, for example due to wear on the drive rollers and pulleys, compression of the cable sleeve, or creep of the pulleys. Therefore, the window regulator must compensate for the cable elongation caused by the aging of the various components.

[0007] In addition, when the window is being raised, the drive motor still applies torque to the window adjustment device when the window reaches its upper limit. Excessive torque at the upper limit can cause elastic deformation of the window regulator components and result in elastic elongation of the cable and other force-bearing units.

[0008] A play compensation mechanism is employed to take up the cable elongation and ensure sufficient tension force for the accurate operation of the window adjustment device. However, these mechanisms consist of multiple components.

[0009] Therefore, a cable tensioner is needed in the window adjustment device that can effectively and efficiently take up the cable elongation and ensure a stable tension force for the correct operation of the window adjustment device. Summary of the Invention

[0010] Disclosed is a tensioner for a window lifter, which is used to raise and lower the vehicle window. The tensioner includes a first tensioner support, a second tensioner support, a spring, and an adjustment sleeve. The spring is disposed between the first tensioner support and the second tensioner support. The adjustment sleeve is configured to engage a feature of the first tensioner support when the second tensioner support moves away from the first tensioner support due to the biasing force of the spring.

[0011] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the feature of the first tensioner support is a plurality of teeth, and the adjustment sleeve has a plurality of arms, each of which extends flexibly from the bottom surface of the adjustment sleeve, and the distal ends of the arms each have a hook.

[0012] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, each of the plurality of arms is separated by a slot, and the slot is received in a feature between the plurality of teeth.

[0013] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, a corresponding feature engages a hook of one of the plurality of arms, so that the adjustment sleeve can slide onto the first tensioner support, and the adjustment sleeve is rotatably received on the first tensioner support until the adjustment sleeve rotates to the slot receiving the feature and the hook engages one of the plurality of teeth, and the feature prevents the adjustment sleeve from rotating relative to the first tensioner support when received in the slot.

[0014] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the adjustment sleeve is partially received in a cavity of the second tensioner support, and the cavity defines a limit of the movement of the plurality of arms away from the first tensioner support.

[0015] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the adjustment sleeve is partially received in a cavity of the second tensioner support, and the adjustment sleeve has a protrusion configured to slide in a recess in the inner surface of the cavity of the second tensioner support. The protrusion has a first surface and a second surface, and the recess has a first side surface and a second side surface. The sliding of the protrusion in the recess defines a predetermined range of relative movement between the second tensioner support and the adjustment sleeve before the tensioner is irreversibly adjusted to a longer length.

[0016] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the spring contacts the boss of the first tensioner support member and the boss of the second tensioner support member in sequence to displace the second tensioner support member from the first tensioner support member.

[0017] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the adjusting sleeve is rotatably received within an opening of the first tensioner support member, and the adjusting sleeve has a plurality of stepped features that engage complementary stepped features located on an inner surface of the opening.

[0018] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the spring is a first spring, and the adjusting sleeve is provided with a rotational biasing force by a second spring.

[0019] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the second spring is a torsion spring, one end of the torsion spring engages an opening in the adjusting sleeve and an opposite end of the second spring engages an opening in the second tensioner support member.

[0020] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, a section of the second tensioner support member has a key structure that allows it to be inserted through and into an opening of the adjusting sleeve, and thereafter rotating the key structure prevents the key structure from sliding back into the opening.

[0021] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the adjusting sleeve is rotatably received within an opening of the first tensioner support member, and the adjusting sleeve has a plurality of stepped features that engage complementary stepped features located on an inner surface of the opening, and a rotational force is applied to the adjusting sleeve by the spring.

[0022] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, one end of the spring engages an opening in the second tensioner support member and an opposite end of the spring engages an elongate opening in the adjusting sleeve.

[0023] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, the adjusting sleeve is also rotatably received within the second tensioner support member, while a feature portion of the second tensioner support member is slidably received within an elongate opening of the first tensioner support member, which allows linear movement of the second tensioner support member relative to the first tensioner support member while preventing rotation of the second tensioner support member relative to the first tensioner support member.

[0024] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, it further includes a washer fixed to the first tensioner support member, the adjustment sleeve is rotatably received within an opening of the first tensioner support member, the adjustment sleeve has a plurality of stepped features that engage complementary stepped features located on an inner surface of the opening, and wherein when the adjustment sleeve rotates relative to the first tensioner support member, the washer has a feature that slides within an elongated opening on a surface of the adjustment sleeve.

[0025] There is also disclosed a tensioner for a window regulator that is configured to raise and lower a vehicle window, the tensioner including: a first tensioner support member; a second tensioner support member; a spring disposed between the first tensioner support member and the second tensioner support member; an adjustment rack slidably mounted within a rib of the second tensioner support member; and a spring-biased tab portion mounted to the first tensioner support member that is configured to engage teeth of the adjustment rack so as to allow the length of the tensioner to irreversibly increase when one end of the adjustment rack contacts a wall of the rib.

[0026] In addition to one or more of the above features, or as an alternative to any of the foregoing embodiments, an end of the spring-biased tab portion is fixed within an opening of the first tensioner support member.

[0027] There is also disclosed a window regulator including: at least one guide rail; at least one slider slidably mounted to the at least one guide rail; at least one cable, each end of the at least one cable being operatively connected to the at least one slider and an opposite end being operatively connected to a cable reel; at least one cable sleeve tube surrounding the at least one cable, the at least one cable being slidably received within the at least one cable sleeve tube; a motor mounted to a housing and operatively connected to the cable reel such that operation of the motor will cause the cable reel to rotate and cause the at least one slider to move along the at least one guide rail; and a tensioner located between the housing and the at least one cable. The tensioner includes: a first tensioner support member; a second tensioner support member; a spring disposed between the first tensioner support member and the second tensioner support member; and an adjustment sleeve configured to engage a feature of the first tensioner support member when the second tensioner support member moves away from the first tensioner support member due to a biasing force of the spring. Description of the Drawings

[0028] The following description should not be considered restrictive in any way. Referring to the drawings, like elements have like numbers:

[0029] Figure 1 is a partial view of a vehicle having a window regulator with a tensioner according to the present invention;

[0030] Figure 2A is a perspective view of a double lift window regulator with a tensioner according to the present invention;

[0031] Figure 2B is a perspective view of a single-lift window regulator with a tensioner according to the present invention;

[0032] Figure 3 This is an exploded view of the tensioner according to an embodiment of the present invention. Figure 3A and Figure 3B The tensioner support and the adjustment sleeve of the tensioner are shown respectively;

[0033] Figure 4 yes Figure 3 Another exploded view of the tensioner shown;

[0034] Figure 5 yes Figure 3 A perspective view of the tensioner shown;

[0035] Figure 6 yes Figure 3 A perspective view of the tensioner shown without the spring and the second tensioner support. Figures 6A to 6C Shows the installation of the adjustment sleeve on the tensioner support;

[0036] Figure 7 yes Figure 3 a cross-sectional view of the tensioner shown;

[0037] Figure 8 is a partially cut-away perspective view of a tensioner according to an alternative embodiment of the present disclosure;

[0038] Figure 9 yes Figure 8 Exploded view of the tensioner shown;

[0039] Figure 10 yes Figure 8 a cross-sectional view of the tensioner shown;

[0040] Figure 11A yes Figure 8 A perspective view of components of the tensioner is shown;

[0041] Figure 11B yes Figure 8 a perspective view of components of the tensioner shown;

[0042] Figure 12 yes Figure 8 Exploded view of the tensioner shown;

[0043] Figure 13 yes Figure 12 An end view of the first tensioner support is shown, Figure 13A It is alongFigure 13 A cross-sectional view taken along line 13A-13A;

[0044] Figure 14 yes Figure 8 A perspective view of the tensioner shown;

[0045] Figure 15 is a side view of a tensioner according to yet another embodiment;

[0046] Figure 16 yes Figure 15 a cross-sectional view of the tensioner shown;

[0047] Figure 17 yes Figure 16 An exploded view of the components of the tensioner is shown. Figure 17A yes Figure 7 End view of Figure 17B yes Figure 17 opposite end views;

[0048] Figure 18A yes Figure 15 a perspective view of components of the illustrated tensioner with the first tensioner support shown in phantom;

[0049] Figure 18B yes Figure 15 a perspective view of components of the tensioner shown;

[0050] Figure 18C yes Figure 15 a perspective view of components of the tensioner shown;

[0051] Figure 19A is a perspective view of a tensioner according to yet another embodiment, with a first tensioner support shown in phantom;

[0052] Figure 19B yes Figure 19A Exploded view of the tensioner shown;

[0053] Figure 20 yes Figure 19A A view of the tensioner shown in ;

[0054] Figure 21 It is along Figure 20 A cross-sectional view taken along line 21-21;

[0055] Figures 22 to 26 yes Figure 20 A view of the components of the tensioner is shown;

[0056] Figure 27 is a perspective view of a tensioner according to yet another embodiment;

[0057] Figure 28 yes Figure 27An exploded perspective view of the tensioner shown;

[0058] Figure 29 yes Figure 27 A cross-sectional view of the tensioner shown; and

[0059] Figure 30 yes Figure 27 A perspective view of the components of the tensioner is shown. DETAILED DESCRIPTION

[0060] A detailed description of one or more embodiments of the disclosed apparatus and method is presented herein by way of example and not limitation with reference to the accompanying figures.

[0061] Disclosed herein is a device for raising and lowering a vehicle window. The device may be referred to as a "window regulator." In one or more embodiments, the window regulator is an electromechanical device controllable by a user inside the vehicle, such as by operating a switch.

[0062] Figure 1 FIG2 is a partial side view of a vehicle 10 having at least one door 12 with a window 14 that is raised and lowered by a window regulator 16 disposed within (e.g., on the exterior and interior) the door panel of the door 12. Although only one door 12 and window 14 are shown, it is contemplated that the window regulator or the present disclosure may be used in vehicles having multiple doors and associated windows. Thus, one or more other windows 14 of the vehicle 10 may also be operated by a window regulator 16 according to the present disclosure. In one embodiment, the window regulator 16 is configured to raise and lower a window of a vehicle having a frameless door.

[0063] Figure 2A is a perspective view of a dual-track window regulator 16. The window regulator 16 includes a pair of rails 18, each having a slider 20 slidably secured to a corresponding rail 18 of the pair of rails 18. The pair of rails 18 may be referred to as a first rail 18' and a second rail 18". In the illustrated embodiment, when the window regulator 16 is secured to the vehicle door, the first rail 18' is closer to the front of the vehicle or door than the second rail 18". Thus, when the window regulator 16 is secured to the vehicle door, the second rail 18" is closer to the rear of the vehicle or door than the first rail 18'. Additionally, the corresponding sliders may be referred to as a first slider 20 and a second slider 20. Each slider 20 is assembled with the vehicle window 14, and each slider 20 is connected by at least one cable or a pair of cables.

[0064] Each of a pair of guide rails 18 of the window regulator 16 may have an upper pulley or upper cam 24 fixed to the top of each guide rail 18. As shown, the upper pulley or upper cam 24 is aligned with the guide rail 18. The upper pulley or upper cam is configured to rotatably or slidably receive a cable. For example, one end of a first cable 22 is fixed to one of a pair of sliders 20 and its opposite end is fixed to a cable reel 28, and one end of a second cable 23 is fixed to the other of the pair of sliders 20 and its opposite end is fixed to the cable reel 28. Additionally, one end of a third cable 27 is fixed to one of the pair of sliders 20 and its opposite end is fixed to the other of the pair of sliders 20. Alternatively, as described above, only one cable is fixed to the sliders 20 and the cable reel 28.

[0065] Figure 2B is a perspective view of a single-guide-rail window regulator 16. The single-guide-rail window regulator includes a guide rail 18 having sliders 20 slidably fixed thereto. The sliders 20 are configured to be fixed to a window 14 and are connected by at least one or a pair of cables.

[0066] The guide rail 18 of the window regulator 16 may have a fixed upper pulley or upper cam 24. The upper pulley or upper cam is configured to rotatably or slidably receive a cable. For example, one end of a first cable 22 is fixed to the slider 20 and its opposite end is fixed to the cable reel 28, and one end of a second cable 23 is fixed to the slider 20 and its opposite end is fixed to the cable reel 28. Alternatively, as described above, only one cable is fixed to the sliders 20 and the cable reel 28.

[0067] The cable reel 28 is rotatably mounted to a housing 30. To provide a rotational movement to the cable reel 28, a motor 32 is operably coupled to the cable reel 28 through, for example, a worm gear (not shown) rotated by the motor 32. In one embodiment, the housing 30 is not fixed to either guide rail 18.

[0068] The guide rail 18 also has a lower pulley or lower cam 34. As shown, the lower pulley or lower cam 34 is aligned with the guide rail 18. The lower pulley or lower cam 34 is configured to rotatably or slidably receive the cable.

[0069] When the cable reel 28 rotates, one of the first cable 22 and the second cable 23 will wind onto the cable reel 28 while the other unwinds, causing the slider 20 to move in the direction of arrow 38. Additionally, the cable 27 not connected to the cable reel 28 will move accordingly. For example, one end of the cable 27 is attached to the top of one slider 20 and its opposite end is attached to the bottom of the other slider 20. The movement of the slider 20 in the direction of arrow 38 will cause the window 14 to move up and down relative to the door 12.

[0070] The window regulator 16 further includes a first cable sleeve 44 for the first cable 22, which extends the guide rail 18 to the housing 30. In addition, a second cable sleeve 40 extends from the housing 30 to the guide rail 18. In addition, a third cable sleeve 42 extends from the rear guide rail 18" and the front guide rail 18'.

[0071] The first cable 22 is slidably received within the first cable sleeve 44, the second cable 23 is slidably received within the second cable sleeve 40, and the third cable 27 is slidably received within the third cable sleeve 42. These cables 22, 23, and 27 and their associated cable sleeve tubes 44, 40, and 42 are referred to as Bowden cables. The second cable sleeve tube 40 further includes a tensioner 41, which, as is known in the relevant art, tightens the slack in the second cable 23. For example, the tension force applied to the lower cable or the second cable 23 is higher than the load applied to the window regulator when moving the window glass in the downward direction (e.g., the load applied to the window regulator in the downward direction = window glass friction - window glass load). Thus, the tensioner 41 of the present disclosure meets the requirements under all conditions (climatic conditions) and throughout the life of all window regulators.

[0072] The controller for controlling the motor 32 and the inputs to the controller, such as a user-operated switch, a door half-open switch, and a vehicle control module (which may also provide inputs to the controller), are not shown. Also not shown is the power supply system, which may include a battery and an alternator, as vehicle power supply systems and window controllers are well known in the art and these components are not discussed further in detail.

[0073] Now referring to Figures 3 to 7 , a tensioner 41 according to the present disclosure is shown. The tensioner 41 includes a first tensioner support 50, a spring 52, an adjustment sleeve 54, and a second tensioner support 56. The adjustment sleeve 54 is slidably mounted to the first tensioner support 50, and the spring 52 provides a biasing force between the first tensioner support 50 and the first tensioner support 50. In a non-limiting embodiment, the first tensioner support 50, the adjustment sleeve 54, and the second tensioner support 56 are formed of a material that is easy to mold, such as plastic.

[0074] The adjustment sleeve 54 is partially received within a cavity 58 of the second tensioner support 56. The adjustment sleeve 54 also has a protrusion 60 configured to slide within a recess 70 located within the inner surface 72 of the cavity 58. When the adjustment sleeve 54 is partially received within the cavity 58, the configuration of the recess 70 and the protrusion 60 define a range of motion of the adjustment sleeve 54 relative to the second tensioner support 56. This range of motion allows for a predetermined amount of slack before the tensioner 41 is irreversibly adjusted to a longer length. For example, this predetermined amount of slack can be referred to as an offset to maintain a frameless window seal in the event that one side of the window does not reach the top, such that the tensioner does not irreversibly eliminate this predetermined amount of slack. The predetermined amount of slack is defined by the range of motion of the protrusion 60 within the recess 70. The inner surface 72 of the cavity 58 is angled with respect to the recess 70 such that when the adjustment sleeve 54 is inserted into the cavity 50, the protrusion 60 will be received within the recess 70 by an interference fit. The protrusion 60 has a first surface 62 and a second surface 64, and the recess 70 has a first side 71 and a second side 73.

[0075] The adjustment sleeve 54 has a plurality of arms 74 that flexibly extend from a body portion 76 of the adjustment sleeve 54, and each distal end of each arm 74 has a hook 78. The plurality of arms 74 are elastic such that they can be moved from a first position by a force, and thereafter, after removal of the force, the plurality of arms can return to the first position. The first tensioner support 50 has a plurality of angled teeth 80 that engage the respective hooks 78 of the plurality of flexible arms 74 when the plurality of flexible arms 74 are in the first position. The hooks 78 and the plurality of angled teeth 80 allow the adjustment sleeve 54 to be extended relative to the first tensioner support 50 in the direction of arrow 82. The engagement of the hooks 78 with the surface 84 of the plurality of angled teeth 80 prevents the adjustment sleeve 54 from moving relative to the first tensioner support 50 in a direction opposite to arrow 82.

[0076] The cavity 58 also provides a limit or range of motion for the plurality of arms 74 away from the plurality of angled teeth 80. This range of motion depends on the position of the adjustment sleeve 54 relative to the second tensioner support 56. For example, in one non-limiting embodiment, each arm 74 also has an outwardly extending protrusion 75 that has an angled surface located near the distal end of the arm 74. The angled surface of the outwardly extending protrusion 75 is configured to contact the angled surface of the cavity 58 in order to provide a limit of motion for the plurality of arms 74 away from the plurality of angled teeth 80. This range of motion (e.g., away from the teeth 80) can depend on the position of the protrusion 60 within the recess 70, as this will determine the position of the angled surface of the outwardly extending protrusion 75 relative to the angled surface of the cavity 58.

[0077] For example, in one non - limiting embodiment, when the second side 73 of the recess 70 of the second tensioner support 56 contacts the second surface 64 of the protrusion 60 of the adjustment sleeve 54, as opposed to when the first side 71 of the recess 70 of the second tensioner support 56 contacts the first surface 62 of the protrusion 60 of the adjustment sleeve 54, a larger portion of the angled surface of the outwardly extending protrusion 75 is received within the cavity 58. When a larger portion of the angled surface of the outwardly extending protrusion 75 is received within the cavity 58, the cavity provides multiple arm portions 74 that have less movement or a smaller range of movement away from the multiple angled teeth 80. Then, when the first side 71 of the recess 70 of the second tensioner support 56 contacts the first surface 62 of the protrusion 60 of the adjustment sleeve 54, at this position (e.g., the first surface 62 contacts the first side 71), the cavity 58 allows the multiple arm portions 74 to have a greater range of movement away from the multiple angled teeth 80 than when the second surface 64 contacts the second side 73. This depends on the relative position of the angled surface of the outwardly extending protrusion 75 with respect to the angled surface of the cavity 58.

[0078] Each of the multiple flexible arm portions 74 is separated by a slot 86 that receives a feature 88 located between the multiple angled teeth 80 when the adjustment sleeve 54 is fixed and / or assembled to the first tensioner support 50. See, for example Figures 6A to 6C . During the assembly of the adjustment sleeve 54 to the first tensioner support 50, the hook 78 is aligned to engage the top of the feature 88 such that the hook 78 does not engage the multiple angled teeth 80, thereby allowing the adjustment sleeve 54 to slide onto the first tensioner support 50 in the direction of arrow 81. Thereafter, once the adjustment sleeve 54 is in the desired position ( Figure 6B ), the adjustment sleeve 54 is rotated in the direction of arrow 83 until the flexible arm portions fall onto the multiple angled teeth 80 between the features 88 such that the features 88 are received within the slots 86. During assembly, the spring 52 contacts the flange 90 of the first tensioner support 50 and the flange 92 of the second tensioner support 56. In a non - limiting embodiment, a washer 91 is located between the flange 92 and the spring 52. When the tensioner 41 is assembled at least as Figure 7 shown, the spring 52 is compressed and the spring 52 contacts the flange 90 of the first tensioner support 50 and the flange 92 of the second tensioner support 56, thereby applying a biasing force in the direction of arrow 94.

[0079] To hold the tensioner 41 and the spring 52 in at least as Figure 7In the compressed state shown, the locating pin 96 is inserted into the opening 98 of the second tensioner support 56 and engages a groove or recess 100 located in the first tensioner support 50. Thereafter, once the tensioner 41 is installed in its desired position, the pin 96 is removed and the spring force is applied in the direction of arrow 94.

[0080] Thus, if there is slack in the cable 23, as described above, the slack will be taken up when the flanges 90 and 92 are moved away from each other in the direction of arrow 94 due to the biasing force of the spring 52. The hook portion 78 of each of the plurality of arms 74 respectively engages one of the plurality of angled teeth 80 of the first tensioner support 50.

[0081] Figure 7 The tensioner 41 is also shown as being secured to the housing 30 by, for example, a section of the first tensioner support 50 being received within a complementary opening 102 of the housing 30. The first tensioner support 50 is relatively slidably received within the cavity 58 and opening 108 of the second tensioner support 56. The first tensioner support 56 also defines an opening 106. Openings 106 and 108 define a path through which the cable 23 slides. Thus, the tensioner 41 provides a means and method for tightening cable slack.

[0082] Now refer to Figures 8 to 14 , shows an alternative embodiment of the present invention in which an adjustment sleeve 54 is rotatably received within the opening 106 of the first tensioner support 50, and the adjustment sleeve 54 has a plurality of step features 110 that engage complementary step features 112 located on the inner surface of the opening 106. Thus, when the adjustment sleeve 54 is rotated relative to the first tensioner support 50 in the direction of arrow 114, and when the second tensioner support 56 is moved away from the first tensioner support 50 in the direction of arrow 94 due to the bias, the length "L" of the tensioner 41 is irreversibly increased due to the configuration of the step features 110 and 112 and their interaction with each other. In this way, slack in the cable 23 is taken up.

[0083] To provide a rotational force to the adjustment sleeve 54 in the direction of arrow 114, a second spring 53 is provided. In one embodiment, the second spring 53 is a torsion spring, wherein one end 116 of the second spring 53 engages an opening 118 in the adjustment sleeve 54 and an opposite end 119 of the second spring 53 engages an opening 120 in the second tensioner support 56.

[0084] The adjusting sleeve 54 is also rotatably received within the second tensioner support 56. This section 104 of the second tensioner support 56 has a key structure 122 that allows it to be inserted into an opening 124 of the adjusting sleeve 54. The key structure 122 allows this section 104 of the second tensioner support 56 to slide into and through the opening 124, after which the section is rotated to hold the adjusting sleeve 54 on the key structure 122. Because the ends 116 and 119 are received within complementary openings 118 and 120 when the second tensioner support 56 rotates relative to the adjusting sleeve 54, this rotation also provides torque to the second spring 53. The torque of the second spring 53 causes the required rotational movement of the adjusting sleeve 54 relative to the first tensioner support 50. However, the tensioner 41 is configured such that the adjusting sleeve 54 does not slip off the section 104 when rotating due to the torque of the second spring 53.

[0085] To hold the first tensioner support 50, the adjusting sleeve 54, and the second tensioner support 56 together and compress the spring 52, a tool 126 is provided. The tool 126 has a pair of yokes 128 connected by a central member 130. The pair of yokes 128 is configured to engage the flanges 90 and 92, and the length of the central member 130 defines the initial state of the spring 52 when the pair of yokes 128 engages the flanges 90 and 92.

[0086] Now referring Figures 15 to 18C , another alternative embodiment of the present disclosure is shown. Here, it is similar to the embodiment Figures 8 to 14 shown. The adjusting sleeve 54 is rotatably received within an opening 106 of the first tensioner support 50, and the adjusting sleeve 54 has a plurality of stepped features 110 that engage complementary stepped features 112 located on the inner surface of the opening 106. Thus, when the adjusting sleeve 54 rotates relative to the first tensioner support 50 in the direction of arrow 114, and when the second tensioner support 56 moves away from the first tensioner support 50 in the direction of arrow 94 due to the biasing force of the spring 52, the length "L" of the tensioner 41 irreversibly increases due to the configuration of the stepped features 110 and 112 and their interaction with each other. In this way, the slack in the cable 23 is taken up.

[0087] To provide a rotational force to the adjustment sleeve 54 in the direction of arrow 114, spring 52 is a torsion spring, where one end 116 of the spring 52 engages an opening 118 in the second tensioner support 56, and the opposite end 119 of the spring 52 engages an elongate opening 120 in the adjustment sleeve 54. The adjustment sleeve 54 is also rotatably received within the second tensioner support 56, while a feature 170 of the second tensioner support 56 is slidably received within an elongate opening 172 of the first tensioner support 50. This permits linear movement of the first tensioner support 50 relative to the second tensioner support 56 while preventing rotational movement relative to each other, such that the torsional biasing force of the spring 52 causes rotational movement of the adjustment sleeve 54 relative to the first tensioner support 50. Thereby causing the length "L" of the tensioner to irreversibly increase in order to take up slack in the cable 23. Thus, in the present embodiment, spring 52 provides at least the Figures 8 to 14 dual function of springs 52 and 53 in the illustrated embodiment.

[0088] Now referring Figures 19A to 26 to, there is shown yet another alternative embodiment of the present disclosure. Here, similar to the embodiment as Figures 15 to 18C illustrated. The adjustment sleeve 54 is rotatably received within an opening 106 of the first tensioner support 50, and the adjustment sleeve 54 has a plurality of stepped features 110 that engage complementary stepped features 112 located on the inner surface of the opening 106. When the adjustment sleeve 54 rotates relative to the first tensioner support 50 and the second tensioner support 56 moves away from the first tensioner support 50 in the direction of arrow 94 due to the biasing force of the spring 52, the length "L" of the tensioner 41 irreversibly increases due to the construction of the stepped features 110 and 112 and their interaction with each other. In this way, the slack portion in the cable 23 is taken up.

[0089] To provide a rotational force to the adjustment sleeve 54, spring 52 is a torsion spring having one end 116 thereof engaging an opening 118 in the second tensioner support 56 and an opposite end 119 of the spring 52 engaging an opening 121 in washer 91. Washer 91 is located near flange 90 which has a projection or feature 250 that engages an elongate opening 252 in the surface of adjustment sleeve 54. As adjustment sleeve 54 rotates relative to the first tensioner support 50, projection or feature 250 slides within elongate opening 252. Adjustment sleeve 54 is also rotatably received within the second tensioner support 56. This permits linear movement of the second tensioner support 56 relative to the first tensioner support 50. The adjustment sleeve 54 will also be pulled away from the first tensioner support 50 by the second tensioner support 56 and the adjustment sleeve 54 will be rotated by spring 53 until step features 110 and 112 engage one another. Due to the construction of step features 110 and 112 and their interaction with one another, this synchronous rotational movement of adjustment sleeve 54 relative to the first tensioner support 50 irreversibly increases the length of tensioner 41. Additionally, as in the previous embodiment, there is a small range of motion (as shown by arrow 99) between adjustment sleeve 54 and the second tensioner support 56 which is provided by the interaction features of adjustment sleeve 54 and the second tensioner support 56. This permits reversible adjustment of length "L" in either direction. As described above, this small range of motion permits absorption of a predetermined amount of slack before the tensioner 41 is irreversibly adjusted to a longer length. For example, this predetermined amount of slack may be referred to as an offset to maintain a frameless window seal in the event that one side of the window does not reach the top such that the tensioner does not irreversibly eliminate this predetermined amount of slack.

[0090] Now referring Figures 27 to 30 , there is shown a tensioner 41 according to yet another embodiment. Tensioner 41 includes a first tensioner support 50, a spring 52, an adjustment rack 55, and a second tensioner support 56. Adjustment rack 55 is slidably mounted to a groove 57 in the second tensioner support 56 and spring 52 provides a biasing force between the first tensioner support 50 and the second tensioner support 56. The construction of groove 57 and adjustment rack 55 defines a range of motion of adjustment rack 55 relative to the second tensioner support 56 when the second tensioner support 56 is partially received within the first tensioner support 50. This range of motion permits tightening of a predetermined amount of slack before the tensioner 41 is irreversibly adjusted to a longer length. As described above, this predetermined amount of slack may be referred to as an offset to maintain a frameless window seal in the event that one side of the window does not reach the top such that the tensioner does not irreversibly eliminate this predetermined amount of slack.

[0091] The tensioner 41 also has a spring-biased tab portion 150 mounted to a first tensioner support 50. The spring-biased tab portion 150 is configured to engage a tooth 152 of the adjustment rack 55 so as to allow the "L" shaped length of the tensioner 41 to increase irreversibly, which occurs when an end 154 of the adjustment rack 55 contacts a wall 156 of the recess 57. In one non-limiting embodiment, the spring-biased tab portion 150 has an end 158 received within an opening 160 of the first tensioner support 50.

[0092] To hold the tensioner 41 and the spring 52 in at least the initial state as Figure 27 shown, a locating pin 96 is inserted into an opening 98 of the first tensioner support 50 and engages an opening 100 located in a second tensioner support 56. Thereafter once the tensioner 41 is installed in its desired position, the pin 96 is removed and the compressive biasing force of the spring 52 is applied to the first tensioner support 50 and the second tensioner support 56.

[0093] Thus, if there is slack in the cable 23, as described above, the slack will be taken up when the first tensioner support 50 and the second tensioner support 56 move away from each other due to the biasing force of the spring 52. As shown, the spring-biased tab portion 150 mounted to the first tensioner support 50 will engage the tooth 152 of the adjustment rack 55 so as to allow the length "L" of the tensioner 41 to increase irreversibly. It should be noted that after the end 154 of the adjustment rack 55 contacts the wall 156 of the recess 57, the tab portion 150 will only slide on the tooth 152, and thereafter the spring-biased tab portion 150 will move irreversibly to the next tooth 152 of the adjustment rack 55.

[0094] Elements of the embodiments have been introduced with the article "a" or "an". These articles are intended to denote the presence of one or more elements. Terms such as "comprising" and "having" are intended to be inclusive so that there may be additional elements other than the listed elements. The conjunction "or" when used with a list of at least two terms is intended to mean any term or combination of terms. The term "configured" relates to one or more structural limitations required for a device to perform its configured function or operation.

[0095] The disclosure illustratively disclosed herein may be practiced in the absence of any element not specifically disclosed herein.

[0096] Although the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its essential scope. Therefore, the present disclosure is not intended to be limited to the particular embodiments disclosed as the best mode contemplated for carrying out the present disclosure, but rather, the present disclosure is intended to include all embodiments falling within the scope of the claims.

Claims

1. A tensioner (41) for a window regulator (16) that raises and lowers a window (14) of a vehicle (10), the tensioner (41) comprising: A first tensioner support member (50); A second tensioner support member (56); A spring (52) disposed between the first tensioner support member (50) and the second tensioner support member (56); and An adjustment sleeve (54) configured to engage a feature of the first tensioner support member (50) when the second tensioner support member (56) moves away from the first tensioner support member (50) due to the biasing force of the spring (52).

2. The tensioner (41) according to claim 1, wherein, The feature of the first tensioner support member (50) is a plurality of teeth (80), and the adjustment sleeve (54) has a plurality of arms (74), each arm extending flexibly from a body portion (76) of the adjustment sleeve (54), and a distal end of each arm 74 has a hook (78).

3. The tensioner (41) according to claim 2, wherein, Each of the plurality of arms (74) is separated by a slot (86) that receives a feature (88) located between the plurality of teeth (80).

4. The tensioner (41) according to claim 3, wherein, Each hook (78) of the plurality of arms (74) engages a corresponding one of the features (88), such that the adjustment sleeve (54) can slide onto the first tensioner support member (50), and the adjustment sleeve (54) is rotatably received on the first tensioner support member (50) until the adjustment sleeve (54) rotates to a position where the slot (86) receives the feature (88) and the hook (78) engages one of the plurality of teeth, and the feature (88) prevents the adjustment sleeve (54) from rotating relative to the first tensioner support member (50) when received within the slot (86).

5. The tensioner (41) according to claim 2, wherein, The adjustment sleeve (54) is partially received within a cavity (58) of the second tensioner support member (56), and the cavity (58) defines a limit to the movement of the plurality of arms (74) away from the first tensioner support member (50).

6. The tensioner (41) according to claim 2, wherein, The adjustment sleeve (54) is partially received within the cavity (58) of the second tensioner support member (56), and the adjustment sleeve (54) has a protrusion (60) configured to slide within a recess (70) in an inner surface (72) of the cavity (58) of the second tensioner support member (56), the protrusion (60) having a first surface (62) and a second surface (64), the recess (70) having a first side (71) and a second side (73), and the sliding of the protrusion (60) within the recess (70) defines a predetermined range of relative movement between the second tensioner support member (56) and the adjustment sleeve (54) before the tensioner (41) is irreversibly adjusted to a longer length.

7. The tensioner (41) according to claim 6, wherein, The spring (52) contacts the boss (90) of the first tensioner support (50) and the boss (92) of the second tensioner support (56) to displace the second tensioner support (56) from the first tensioner support (50).

8. The tensioner (41) according to claim 1, wherein, The adjusting sleeve (54) is rotatably received within an opening (106) of the first tensioner support (50), and the adjusting sleeve (54) has a plurality of stepped features (110) that engage complementary stepped features (112) located on an inner surface of the opening (106).

9. The tensioner (41) according to claim 8, wherein, The spring (52) is a first spring, and the adjusting sleeve (54) is provided with a rotational biasing force by a second spring (53).

10. The tensioner (41) according to claim 9, wherein, The second spring (53) is a torsion spring. One end (116) of the torsion spring (53) engages an opening (118) in the adjusting sleeve (54), and an opposite end (119) of the second spring (53) engages an opening (120) in the second tensioner support (56).

11. The tensioner (41) according to claim 10, wherein, A section (104) of the second tensioner support (56) has a key structure (122) that allows it to be inserted through and into an opening (124) of the adjusting sleeve (54), and rotation of the key structure (122) thereafter prevents the key structure (122) from sliding back into the opening (124).

12. The tensioner (41) according to claim 1, wherein, The adjusting sleeve (54) is rotatably received within an opening (106) of the first tensioner support (50), and the adjusting sleeve (54) has a plurality of stepped features (110) that engage complementary stepped features (112) located on an inner surface of the opening (106), and a rotational force is applied to the adjusting sleeve (54) by the spring (52).

13. The tensioner (41) according to claim 12, wherein, One end (116) of the spring (52) engages an opening (118) in the second tensioner support (56), and an opposite end (119) of the spring (52) engages an elongated opening (120) in the adjusting sleeve (54).

14. The tensioner (41) according to claim 13, wherein, The adjusting sleeve (54) is also rotatably received within the second tensioner support (56), while a feature (170) of the second tensioner support (56) is slidably received within an elongated opening (172) of the first tensioner support (50) to permit linear movement of the second tensioner support (56) relative to the first tensioner support (50) while preventing rotation of the second tensioner support (56) relative to the first tensioner support (50).

15. The tensioner (41) according to claim 1, wherein, Further includes a washer (91) fixed to the first tensioner support member, the adjustment sleeve (54) is rotatably received within an opening (106) of the first tensioner support member (50), the adjustment sleeve (54) has a plurality of stepped features (110), the stepped features (110) engage complementary stepped features (112) located on the inner surface of the opening (106), and wherein when the adjustment sleeve (54) rotates relative to the first tensioner support member (50), the washer has a feature portion (250) that slides within an elongated opening (252) on the surface of the adjustment sleeve (54).

16. A tensioner (41) for a window regulator (16), the window regulator (16) for raising and lowering a window (14) of a vehicle (10), the tensioner (41) comprising: A first tensioner support member (50); A second tensioner support member (56); A spring (52) disposed between the first tensioner support member (50) and the second tensioner support member (56); An adjustment rack (55) slidably mounted in a convex groove (57) of the second tensioner support member (56); and A spring-biased tab portion (150) mounted to the first tensioner support member (50), the spring-biased tab portion (150) engaging teeth (152) of the adjustment rack (55) so as to allow the length of the tensioner (41) to increase irreversibly when one end (154) of the adjustment rack (55) contacts a wall (156) of the groove (57).

17. The tensioner (41) according to claim 16, wherein, An end portion (158) of the spring-biased tab portion (150) is fixed within an opening (160) of the first tensioner support member (50).

18. A window regulator (16) comprising: At least one guide rail (18); At least one slider (20) slidably mounted to the at least one guide rail (18); At least one cable (23), each end of the at least one cable (23) being operatively connected to the at least one slider (20) and the opposite end being operatively connected to a cable reel (28); At least one cable sleeve tube (40) surrounding the at least one cable (23), the at least one cable (23) being slidably received within the at least one cable sleeve tube (40); A motor (32) mounted to a housing (30), the motor (30) being operatively connected to the cable reel (28) such that operation of the motor (32) will cause the cable reel to rotate and cause the at least one slider (20) to move along the at least one guide rail (18); A tensioner (41) located between the housing (30) and the at least one cable (40), the tensioner comprising: A first tensioner support member (50); A second tensioner support member (56); A spring (52) disposed between the first tensioner support (50) and the second tensioner support (56); and An adjustment sleeve (54) configured to engage a feature of the first tensioner support (50) when the second tensioner support (56) moves away from the first tensioner support (50) due to the biasing force of the spring (52).

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