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| CLAIMS: 1. A ferrule and wire pack for replacement of an original wire having at least one ferrule crimped to it in a predetermined position, the pack comprising: • at least one replacement wire and · at least one replacement ferrule having: • a body of a size manually-crimpable to the wire and cross-sectionally smaller than the ferrule to be replaced and • a part having a larger cross-sectional size, corresponding to that of the ferrule to be replaced. 2. A ferrule and wire pack as claimed in claim 1 , wherein the ferrules and cable are sized and shaped to be used in a window regulator 3. A ferrule and wire pack as claimed in claim 1 or claim 2, wherein the cable is of stainless steel. 4. A ferrule and wire pack as claimed in claim 1, claim 2 or claim 3, wherein the ferrule is of polymeric material. 5. A ferrule and wire pack as claimed in any preceding claim, wherein the larger part of at least one of the replacement ferrule(s) is a flange integral with its body. 6. A ferrule and wire pack as claimed in claim 5, including at least one outer part sized to fit as a sleeve over the body. 7. A ferrule and wire pack as claimed in any one of claims 1 to 4, wherein the larger part of at least one of the replacement ferrule(s) is an outer part sized to fit as a sleeve over the body. 8. A ferrule and wire pack as claimed in claim 7, wherein the outer part is longer than the body and has a counter-bore sized to receive the body and a smaller bore to receive the wire at one end. 9. A ferrule and wire repair pack as claimed in any preceding claim, wherein the or each body is tubular. 10. A ferrule and wire repair pack as claimed in claim 9, wherein the or each body has a circular cylindrical exterior to its body. 1 1. A ferrule and wire repair pack as claimed in any preceding claim, including a manual crimping tool for crimping the manually-crimpable body to the replacement wire. 12. A ferrule and wire repair pack as claimed in any preceding claim, including replacement ferrules of the same diameter, but of a differing lengths of bodies and/or outer parts, where provided. 13. A ferrule and wire repair pack as claimed in claim 12, including outer parts of a length to bridge two bodies having flanged ends. 14. A ferrule and wire pack for replacement of an original wire as claimed in any preceding claim, the wire being a window regulator wire, the pack including wire replacement instructions. 15. A ferrule and wire repair pack as claimed in claim 14, wherein the instructions for use in replacing wires in window regulators having a slider on a track, a manual or electrical winch and a single wire passing from the winch to the slider in one run and back to the winch on its opposite side in another run or a pair of wires corresponding to the two runs, includes the followings steps: • clamping the slider in a position on its track, • attaching a ferrule at one end of the wire, • securing the ferrule in the winch, with an appropriate length of wire on the winch for positioning of the slider, • running wire from the winch to the slider, • attaching one or more ferrules to the wire at the slider and engaging the ferruled wire with the slider, • running wire to the winch and noting the position of a further ferrule for attaching the wire to the winch, with the wire tensioned, • attaching this further ferrule to the wire and engaging it on the winch. 16. A ferrule and wire pack as claimed in claim 14, wherein the instructions for use in replacing wires in window regulators having a slider on a track, a manual or electrical winch and two wires passing from the winches to the slider, and from the slider back to the winch on its opposite side, includes the following steps:- • clamping the slider in a position on its track, • attaching a ferrule at one end of the first wire, • securing the ferrule in the winch, with an appropriate length of wire on the winch for positioning of the slider • attaching a ferrule at one end of the second wire • securing the ferrule in the winch, crimping a final ferrule on the second wire at the slider in a position corresponding to the wires being tensioned. |
The present invention relates to ferrule fixture, that is to say a method of fixing a ferrule and ferrules for the method.
Conventionally, certain window regulators fitted to automobiles have stop ends or ferrules swaged or crimped to the inner part of a Bowden cable. In this specification, the terms "ferrule" and "crimped" are used. Such arrangement does not permit ready replacement of the cables outside well-equipped factory or workshop premises, due to the requirement for equipment to form the crimp and a lack of guidance as to the appropriate methodology.
In my patent application, No. PCT/GB2009/000139 (My Prior Application), I have described and claimed:
A method of fixing a ferrule onto a laid-up cable, the method consisting in the steps of:
• providing a tapered or stepped ferrule having a larger diameter internal bore at one end and a smaller diameter internal bore at the other end,
· threading the ferrule onto the cable with the larger diameter internal bore opening towards an end of the cable,
• unlaying the end of the cable to cause it to splay out to a transverse size
greater than the small diameter internal bore,
• applying to the cable, at least at the unlaid portion thereof, adhesive adherent to the cable,
• drawing the unlaid portion of the cable, together with adhesive applied to it, into the larger diameter bore end of the ferrule and allowing the adhesive in the larger diameter bore end to set, whereby the set adhesive holds the end of the cable in its splayed condition in the larger diameter end to resist drawing of the cable from the ferrule via the smaller diameter end.
The method of My Prior Application has, I believe, proved satisfactory for many users. Nevertheless it involves some dexterity. Crimping of ferrules is quicker and easier where suitable tools are available. However, certain window regulators, the primary use of my prior method, include ferrules that are too large to be crimped without use of a hydraulic press or possibly an unwieldy mechanical tool. Small ferrules can be crimped with hand tools, but these are usually expensive. There is a need for inexpensive replacement of the larger ferrules in window regulators.
The object of the present invention is to provide an improved ferrule fixture method.
According to the invention there is provided a ferrule and wire pack for replacement of an original wire having at least one ferrule crimped to it in a predetermined position, the pack comprising:
• at least one replacement wire and
• at least one replacement ferrule having:
• a body of a size manually-crimpable to the wire and cross-sectionally smaller than the ferrule to be replaced and
• a part having a larger cross-sectional size, corresponding to that of the ferrule to be replaced. The invention is particularly applicable to repair of the cables of a window regulator in an automobile, in which case the ferrules and the cable are sized and shaped to be used in a window regulator.
The cable will normally be of metal, preferably stainless steel, but can be of polymeric material. The ferrule can be of metal or other engineering materials, but will normally be of polymeric material.
The larger part of at least one of the replacement ferrule(s) can be a flange integral with its manually-crimpable body. In this case, the pack can include at least one outer part sized to fit as a sleeve over the manually-crimpable body.
Alternatively the larger part of at least one of the replacement ferrule(s) can be an outer part sized to fit as a sleeve over the manually-crimpable body; and in this case the outer part is longer than the manually-crimpable body and has a counter-bore sized to receive the body and a smaller bore to receive the wire at one end. Further alternatives that can be envisaged are that the ferrule could have two small diameter manually-crimpable body portions one on either side of a large diameter portion and that the ferrule could have two larger diameter portions with a small diameter manually-crimpable body portion in between.
Except where additional wires and ferrules are supplied alone, the pack will normally include a manual crimping tool for crimping the manually-crimpable body to the replacement wire.
Additionally the pack will normally include instructions for use in replacing wires in window regulators having a slider on a track, a manual or electrical winch and a single wire passing from the winch to the slider in one run and back to the winch on its opposite side in another run or a pair of wires corresponding to the two runs. These include the steps of:
• clamping the slider in a position on its track,
• attaching a ferrule at one end of the wire,
• securing the ferrule in the winch, with an appropriate length of wire on the winch for the positioning of the slider,
· running wire from the winch to the slider,
• attaching one or more ferrules to the wire at the slider and engaging the ferruled wire with the slider,
• running wire to the winch and noting the position of a further ferrule for attaching the wire to the winch, with the wire tensioned,
· attaching this further ferrule to the wire and engaging it on the winch.
These steps are appropriate for a single wire or a double wire window regulator with ferrule(s) attaching the slider. Alternatively in the latter case, instead of making the final attachment to the winch, the second wire can be first secured to the winch in the manner of the first wire and the final ferrule can be crimped at the slider in a position corresponding to the wires being tensioned. To help understanding of the invention, a specific embodiment thereof will now be described by way of example and with reference to the accompanying drawings, in which:
Figure 1 is a side view of a conventional, large diameter ferrule crimped to a wire;
Figure 2 is a cross-sectional end vi ew of the large ferrule showing the degree of crimping on the line Π-ΙΙ;
Figure 3 is a side view of a small diameter ferrule and its sleeve as used in the invention;
Figure 4 is a view of a manual crimping tool for the small diameter ferrule;
Figure 5 is a view similar to Figure 3 of another ferrule of the invention; Figure 6 is similar view of another variant of Figure 3;
Figure 7 is a diagrammatic view of a typical single-lift, automotive window regulator configuration; and
Figure 8 is a diagrammatic view of a typical double-lift, automotive window regulator configuration.
Referring to Figures 1 and 2, a wire 1 is shown with a machine crimped ferrule 2, pressed on four sides to square cross-section in its middle. Such wires and ferrules find wide use, particularly in automotive window regulators. They are not susceptible of replacement with a workshop replaced ferrule, unless the workshop is equipped with a press able to exert more force than a manual crimping tool. Typically the ferrule is 6mm in diameter or larger. With a 1.5mm diameter wire, the wire will normally snap before it pulls out of the ferrule under tension.
Shown in Figure 3 is a first, two part ferrule of the invention, comprised of a small diameter ferrule 1 1 manually crimped to its wire 12 by a conventional manual, pliers like tool 14, having crimping dies 15 on its jaws 16, as shown in Figure 4. The dies are shown hexagonal, which is typical. However, other shapes are possible. Typically, such a tool is suitable for crimping ferrules up to 4.5mm in diameter in single handed operation, with aluminium ferrules. The ferrule 11 as shown is 4.2mm in diameter and 6mm in length - 1 have found this to be a widely useful size. Such a ferrule is likely to pass through an abutment A with an internal bore I against which a larger ferrule rests in use. The ferrule 1 1 is provided with an outer sleeve 17, having a small bore 18 through which the wire 12 passes and a larger counter-bore 19 into which the ferrule 11 fits. The combination of the ferrule 11 and the sleeve 17 makes up the size of the larger ferrule such as 2, in particular with the sleeve having a 6mm outside diameter, whereby it can be used with the abutment A in replacement of the larger ferrule.
Turning on to Figure 5, a small diameter ferrule 21 has a flange 24. It can be crimped manually to its wire 22 being small enough in its plain portion 211 for this. The flange is the same diameter as a larger ferrule 121 that the ferrule 21 is to replace. It can be used on its own with the flange acting via its outer face 241 against an abutment A facing in one direction, or in conjunction with a plain sleeve 27 fitting over the small diameter portion 211 and acting at the free end of the sleeve against an abutment AA facing in the other with the other end of the sleeve abutted against the inner face 242 of the flange.
It will be appreciated the differing large diameter ferrules can be replaced with flanged and sleeved small diameter ferrules.
In certain regulators, the large diameter ferrules are crimped to square shape along their length. These can be reproduced by use of sleeves of square cross-section. These may be counter-bored to receive circular flanges on small diameter bodied ferrules.
One further variant is the use of a flanged ferrule to transmit load to a counter- bored sleeve as in Figure 3, with load being transferred to the end face of the sleeve from the flange, as opposed to internally to the counter-bore face of the sleeve from the end of the crimped small diameter ferrule.
In a variation of the ferrule of Figure 3, the two-part ferrule shown in Figure 6 has a small diameter ferrule 31 and an outer sleeve 32, having a counter-bore for the ferrule 31 and a flange 33, typically of 8mm diameter, at the end of a cylindrical portion 34, typically of 6mm diameter. This arrangement allows an abutment on one side flange for a spring S located on the portion 34. In a typical single-lift, automotive window regulator 101 as shown in Figure 7, a winch drum 102, which can be manually or electrically operated, has two cables 103,104 extending from it in opposite directions. The cables have outer sheaths 1031,1041 and inner wires 1032,1042. At the winch the outer sheaths abut sockets 1033,1043, resiliently carried on a winch chassis 105, with springs 1034, 1044 acting against spring locators 1035,1045 carried on the chassis to tension the wires
1032,1042. Typically, at the ends of the sheaths remote from the winch, they abut pulley fittings 1036,1046 having pulleys 1037,1047 around which the wires pass to extend to a slider 106 on a track 107, the pulley fittings being carried on the ends of the track. In some regulators, pulleys are not used and the wires pass over plain guides, in others again pulleys are used at the top of the track where the wires are more heavily loaded and plain guides are used at the bottom. As shown, the slider has a ledge for carrying window glass; other arrangements are used. The slider ends of the wires 1032,1042 often have large diameter ferrules crimped to them, with the slider having abutments for these ferrules. As shown, these ferrules can be replaced with ferrules of the invention as shown in Figure 3. Alternatively the original ferrules can be small diameter ferrules which can be replaced without the need for outer sleeves. Insofar as the abutments A are conventional, they are not shown in detail. The winch ends of the wires have small diameter ferrules, locating in corresponding sockets in the winch.
When one 1032 of the wires breaks, normally the lift wire, the other is left in place. A small replacement ferrule is manually crimped to the winch end of a replacement wire. The ferrule is engaged in its seat in the winch and the wire wound around the winch for the same number of turns that the old wire was. The wire is fed through the socket, spring and spring locator 1033,1034,1035 and the sheath 1031, on round the pulley 1037 to the slider 106. To determine the length of the wire and the position at which a replacement ferrule is to be placed, the slider is drawn towards the pulley 1037, with the drum being held by internal friction in the manual winder or motor drive, so as to compress the spring 1044. if need be. The slider is clamped in position, with the wire which was left in place tensioned and compressing its spring 1044. Alternatively, with a winder or drive that does not stay locked with internal friction both the winch and the slider are clamped again with the spring compressed. The free end of the replacement wire is tensioned against the other spring and the position at which a second, large replacement ferrule should be crimped on is noted. According to whether a ferrule as in Figure 3 or Figure 5 or Figure 6 is to be used, the position of the small ferrule or the small diameter portion of the flanged ferrule is noted. It is manually crimped on with the flange towards the proximal side or with the sleeve threaded onto the wire first. The wired is re-tensioned and the replacement ferrule fitted to its abutment.
If both wires are broken, the first wire is measured by moving the slider to one end of its track and measuring the length of wire necessary to extend from it, along the track, through the sheath and around the drum to the ferrule abutment, with the drum positioned to provide an appreciable length of contact with the drum. The second wire is fitted as described in the previous paragraph. If necessary, a dummy wire can be used and crimping positions noted on it. This is particularly
advantageous if the regulator requires for a single wire to be used from one side of the winch, to the slider and back to the other side of the winch. In this case, the new wire is fitted from one side of the winch to the slider and the dummy wire with a ferrule is fitted to the other side of the winch; then with both wires tensioned the length of the new wire onto the winch can be noted with reference to the dummy wire. It should also be noted that where a single wire is employed, space may be restricted at the slider. For this situation, I have determined that it is possible to use 4.2mm diameter by 4mm long ferrules, although 4.2mm by 6mm remains preferable where possible.
Referring to Figure 8, in a typical double-lift, automotive window regulator 201, a winch drum 202 has two cables 203,204 extending from it in opposite directions. The first cable 203 passes to a slider 206 on a first track 207. A third cable 205 connects the first slider 206 to a second slider 208 on a second track 209, both ends of both tracks having pulley or guide fittings for guiding the cable wires into the cable sheathes. The cable 204 passes from track 209 to winch drum 202 thus completing the loop. This arrangement allows the two sliders to move in phase along their tracks. The wires can be replaced in analogous manner to that of the single lift regulator described above, whether it has one wire from winch to winch, two wires with one passing from the winch to one slider and on to the next and the second wire back to the winch or three wires - one for each cable run. When a wire breaks in an assembly having discrete wires in each cable, replacement ferrules can be applied at the wire ends as for a single-lift, regulator. In more detail, where one of the wires is intact, it is tensioned and its slider is clamped in place to retain the wire tension. If the intermediate wire between the sliders is intact, it is retained or a new wire is made up by crimping a replacement ferrule at one end and measuring the position for the one at the other end - such that the window glass is level - and crimping the replacement ferrule accordingly. The broken other end wire can then be made up as for a single lift regulator. If the original first wire is to be replaced, this can now be done.
Where ferrules are attached at mid-wire positions in a window regulator assembly comprising a single wire running through the three cables, replacement ferrules are manually crimped at mid-positions on the wire, as described above to arrange for the sliders to be level. Then with the sliders at one end of the tracks, the wire is measured along the longest extent back to the drum, i.e. along the track, through the cable sheath and around a sufficient extent of the drum as described previously. One replacement ferrule is crimped on at this position. The drum is rotated to bring the sliders to the other end of the track; the wire is tensioned, measured to its abutment on the drum and this end ferrule crimped on.
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