Window Regulator Cable Guide Snap-Fit Assembly

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Solution Overview

Problem

Conventional cable guides for automotive window regulator assemblies are heavy, costly, and difficult to assemble, while also requiring complex manufacturing processes and resulting in noise due to unsupported cable vibrations.

Innovation Solution

A cable guide with a body featuring a guide rail region and a cable region, including snap tabs and cantilevered cable retention arms that securely attach to the guide rail, reducing noise and rattle by supporting the drive cable and simplifying assembly through a more straightforward attachment method.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cable guides are used with welding or TOX joining, then the cable guide provides satisfactory performance in supporting the cable, but the manufacturing process becomes complex and costly

Engineering Contradiction:

Improvecable support performanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical joining processes (welding or TOX) with a snap-fit mechanical attachment system. The cable guide includes attachment members that engage with corresponding features on the guide rail, allowing assembly through simple insertion and engagement without thermal or interlocking processes. This substitution simplifies manufacturing while maintaining reliable cable support.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cable guide is divided into separate functional components: the main guide body and attachment members. This segmentation allows each component to be manufactured independently using simpler processes, then assembled together, reducing overall manufacturing complexity while maintaining structural integrity and cable support performance.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional cable guides are used with welding or TOX joining, then the cable guide provides satisfactory performance in supporting the cable, but the assembly process becomes difficult

Engineering Contradiction:

Improvecable support performanceVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces complex mechanical joining operations (welding or TOX) with a simple snap-fit engagement system. The attachment members are designed to engage with the guide rail through straightforward insertion and mechanical locking, making assembly easier and more accessible while maintaining reliable cable support performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conventional cable guides are used with welding or TOX joining, then the cable guide provides satisfactory performance in supporting the cable, but the weight and cost increase

Engineering Contradiction:

Improvecable support performanceVSAvoidcable guide weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent changes the material parameters and joining method parameters to reduce weight. By using lighter materials compatible with snap-fit assembly and eliminating the need for heavy-duty welding or TOX joining structures, the cable guide achieves reduced weight while maintaining adequate cable support performance through the simplified attachment design.

Inventive Principle:

Principle #35Parameter changes

4Volume of moving object

If the electric motor and cable drum are located near the bottom of the guide rail, then packaging constraints are satisfied, but the cable spans the length of the guide rail unsupported causing noise

Engineering Contradiction:

Improvepackaging space utilizationVSAvoidcable vibration noise

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The cable guide acts as an intermediary component that provides support for the cable spanning between the motor assembly and the window carrier. By introducing this intermediate support structure, the cable is prevented from vibrating freely, reducing noise while allowing the motor to remain positioned near the bottom of the guide rail to satisfy packaging constraints.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10501978B2Window regulator cable guide

Publication Date: 2019.12.10 HI LEX CONTROLS INC

AI summary

A cable guide for use with a window regulator assembly includes a body with a first rail support surface, a second rail support surface and a third rail support surface in a guide rail region and a cable support surface and a cable retention arm in a cable region. The first rail support surface is configured to be inserted through an aperture in a guide rail and be placed on a first side of the guide rail and a cable retention arm configured to receive a tensioned drive cable of the window regulator. The cable guide with the first, second and third rail support surfaces may be steadily assembled to the guide rail by utilizing the pushing force from the tensioned drive cable. The aperture is located along the guide rail such that the aperture is out of the slide path of the window carrier of the window regulator assembly.