BACKGROUND OF THE INVENTION

[0001] Assembling and repairing vehicles requires, in part, aligning and securing a glass panel (i.e., windshield) to a body of the vehicle. The installation process includes allowing the glass to adhere to the necessary adhesives in order to secure the windshield relative to the body of the vehicle. However, windshields are often heavy, which make them difficult to manipulate and align, and may include a variety of dimensions (i.e., width, height, thickness etc.) and surface contours.

SUMMARY OF THE INVENTION

[0002] The present invention relates to a windshield repair tool, such as a jack for aligning, stabilizing, and suspending glass panels on a vehicle.

[0003] In one embodiment, the invention provides a jack that is adjustable to accommodate glass panels of various shapes, sizes, and contours. The jack includes a stabilizing member having a suction cup and a handle. The stabilizing member is connected to an adjustable shaft assembly by a spherical joint that allows movement about three axes relative to a longitudinal axis of the jack. The adjustable shaft assembly is coupled to a foot or anchoring member. The foot also includes a first groove and a second groove for placement of the foot against a mounting surface. The adjustable shaft assembly includes an outer tube fixed relative to an inner tube that is slidable therein by a cam lock assembly. The cam lock assembly includes a first cylinder coupled to a second cylinder by a rivet or fastener that extends through first and second apertures extending through first and second cylinders, respectively. The inner and outer tubes are rotated relative to one another to lock and unlock the cam lock assembly.

[0004] In another embodiment, the invention provides a windshield installation device including a suction member configured to be removably coupled to the windshield and a foot including a groove. The device further includes an adjustable shaft assembly that extends between the suction member and the foot. The adjustable shaft assembly includes an outer tube configured to receive an inner tube wherein the inner tube is slidable relative to the outer tube to adjust a distance between the suction member and the foot. The inner tube is also rotatable relative to the outer tube to secure the inner tube to the outer tube.

[0005] In another embodiment, the invention provides a windshield installation device including a suction member configured to be removably coupled to the windshield and a foot including a groove. The device further includes an adjustable shaft assembly that extends between the suction member and the foot. The adjustable shaft assembly includes an outer tube, an inner tube configured to be received within and movable relative to the outer tube, and a threaded shaft coupled to the foot and the inner tube.

[0006] In another embodiment, the invention provides a method for installing a windshield using a windshield installation device, which includes a suction member configured to be removably coupled to the windshield, a foot including a groove, and an adjustable shaft assembly extending between the suction member and the foot. The device also includes an inner tube received within and movable relative to an outer member. A threaded shaft extends from the foot and is threadingly coupled to the inner tube. The method includes coupling the suction member to the windshield, adjusting a position of the inner tube relative to the outer tube, securing the inner tube relative to the outer tube, and moving the threaded shaft relative to the inner tube to define a length between the suction member and the foot. The method also includes positioning the foot on the vehicle and moving the windshield into an installed position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a perspective view of a windshield replacement tool according to one embodiment of the invention.

[0008] FIG. 2 is an exploded view of the windshield replacement tool of FIG. 1. [0009] FIG. 3 is a cross-sectional view of the windshield replacement tool of FIG. 1. [0010] FIGS. 4-5 are enlarged views of a cam lock mechanism.

[0011] FIGS. 6-8 are side views of the windshield replacement tool of FIG. 1 illustrating the various modes of adjustability. [0012] FIG. 9 is a perspective view of a windshield replacement tool according to another embodiment of the invention.

[0013] FIG. 10 is a perspective view of the windshield replacement tool of FIG. 1 relative to a glass panel and a fixed surface.

DETAILED DESCRIPTION

[0014] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

[0015] FIGS. 1-8 illustrate a windshield repair tool or jack 10 according to one embodiment of the invention. The jack 10 includes an attachment or stabilizing member 20, a foot assembly or anchoring member 50, and an adjustable shaft assembly 80 therebetween.

[0016] The stabilizing member 20 includes a first side 22 and a second side 24. The first side 22 includes a suction cup 26, while the second side 24 includes a mounting surface 28. A handle 30 is coupled to the mounting surface 28. In the illustrated embodiment, the handle 30 is fixed to the mounting surface 28; in alternate embodiments, the handle 30 may be pivotable relative to the mounting surface 28 and can activate a vacuum within the suction cup 26. The mounting surface 28 is also coupled to a connector 32 that includes an aperture 34. The connector 32 may be coupled directly to the mounting surface 28, or alternatively, to an auxiliary mount area 36, as illustrated in FIGS. 1-8. Additionally, the mounting surface 28, handle 30, auxiliary mount area 36, and connector 32 may be integrally formed or may be coupled by any suitable means (i.e., secured by one or more fasteners 38). While the mounting surface 28 is illustrated as a rounded, convex surface, the mounting surface 28 may include any suitable configuration.

[0017] The foot assembly 50 includes a generally rectangular body 52 defined by a top surface 54, a bottom surface 56, a front surface 58, a rear surface 60, a first side surface 62, and a second side surface 64. The foot body 52 is constructed from a rigid material, such as steel or other suitable metal and surrounded by a rubber pad or coating. In other embodiments, the foot body 52 may be constructed entirely from a rubber material. A threaded shaft 66 is rigidly coupled to hood bracket 67, which is secured to the foot body 52 such that the threaded shaft 66 extends from the top surface 54 of the foot 50. The shaft 66 includes a threaded lock nut 69 coupled thereto. The shaft 66 provides for precise adjustment of the windshield glass set (both during the dry set and final set).

[0018] The foot body 52 includes a first groove 68 that extends from the first side surface 62 to the second side surface 64 along the bottom surface 56. The first groove 68 is oriented perpendicularly with respect to a longitudinal axis A of the jack 10. The foot body 52 further includes a second groove 70 that extends along the bottom surface 56 from the front surface 58 to the rear surface 60. The second groove 70 is oriented perpendicularly with respect to both the longitudinal axis A and the first groove 68. In the illustrated embodiment, the grooves 68, 70 are substantially V-shaped. It is contemplated that the grooves 68, 70 may be configured to have any suitable shape.

[0019] The adjustable shaft assembly 80 includes an outer tube 82, an inner tube 84, and a cam lock assembly 86. The outer tube 82 defines a first diameter 88 and includes a first end 90 and a second end 92. A binding 94 coupled to the first end 90 of the outer tube 82 includes a through-hole 96 extending therein. The through-hole 96 defines a second, threaded diameter 98. The second end 92 of the outer tube 82 slidably receives the inner tube 84. The inner tube 84 defines a first diameter 100 and includes a first end 102 and a second end 104. The cam lock assembly 86 is coupled to the first end 102 of the inner tube 84. A binding 106 coupled to the second end 104 of the inner tube 84 includes a through-hole 108 extending therein. The through- hole 108 defines a second, threaded diameter 110. The inner tube 84 is configured to slide along the axis A within the outer tube 82 thereby allowing the length of the shaft 80 to be adjusted. Additionally, the inner tube 84 and the outer tube 82 are rotatable relative to one another, the significance of which is described in further detail below. The outer tube 82 is covered by a grip 112 that is constructed from foam or other suitable material that enhances gripability. [0020] In the embodiment illustrated in FIGS. 1-8, a retaining member 180 is optionally used with the adjustable shaft assembly 80 to prevent side-to-side motion of the shaft 80. The retaining member 180 is not required for operation of the jack 10. The retaining member 180 includes an integrally formed body portion 182 having a U-shaped intermediate portion 188 that couples a first leg 184 to a second, opposite leg 186. The legs 184, 186 are at substantially right angles (i.e., about 90° angles) relative to the intermediate portion 188 of the retaining member 180. Each of the first and second legs 184, 186 includes a suction member 190. The

intermediate portion 188 of the retaining member 180 is sized to removably receive the outer tube 82 and the grip 112 of the adjustable shaft 80. The intermediate portion 188 imparts a light squeeze on the grip 112 of the adjustable shaft 80 such that the adjustable shaft 80 retains the capability to be extended and retracted (i.e., the adjustment shaft 80 accommodates up, down, and twisting movement). Further, the height of the retaining member 180 is such that a clearance remains between the shaft 80 and the intermediate portion 188 over a full range of motion of the jack 10.

[0021] Further embodiments of the retaining member 180 may include a body portion 182 having any suitable configuration. For example, as illustrated in FIG. 9, an alternate

embodiment of the retaining member 180' includes a body portion 182' having an intermediate portion 188' coupled to and configured to be in the same plane as legs 184', 186'. As such, the intermediate portion 188' and the legs 184', 186' removably receive the adjustable shaft assembly 80 to impart a light squeeze about grip 112.

[0022] In the illustrated embodiments, the retaining member 180, 180' includes a U-shaped intermediate portion 188, 188' but it should be understood that the intermediate portion may include other suitable shapes and configurations. Similarly, while suction member 190, 190' are illustrated as a means of adhering the retaining member 180 to a surface (e.g., a windshield), any suitable coupling means may be used.

[0023] With reference to FIGS. 2-5, the cam lock assembly 86 allows the shaft assembly 80 to be longitudinally adjustable. The cam lock assembly 86 includes a first cylinder 114 having a first aperture 116 that is offset from the center of the first cylinder 114 and a second cylinder 118 having a second aperture 120 that is offset from the center of the second cylinder 118. The first cylinder 114, which is constructed from a rigid plastic, is mounted to the first end 102 of the inner tube 84. The first cylinder 114 may be mounted to the inner tube 84 by any suitable type of adhesive; alternatively, the first cylinder 114 and the inner tube 84 may be integrally molded. A rivet or fastener 122, which extends through the first and second apertures 116, 120, couples the second cylinder 118 to the first cylinder 114. When coupled, the first and second apertures 116, 120, which are offset from the centers of the first and second cylinders 114,118, are also offset from one another. The second cylinder 118 is rotatable about the rivet 122, but the rivet 122 fixes the second cylinder 118 longitudinally with respect to the first cylinder 114, and therefore the inner tube 84. The second cylinder 118 is constructed from a softer, compressible material, such as rubber, that is capable of creating a friction fit. First and second washers 124 are included on opposite ends of the rivet 122.

[0024] With respect to FIG. 5, the cam lock assembly 86 includes an unlocked position 128 and a locked position 130. In the unlocked position 128, the second cylinder 118 makes slight contact with an inner wall 132 of the outer tube 82 and therefore, the inner tube 84 is slidable relative to the outer tube 82. In the locked position 130, the second cylinder 118 is firmly pressed against the inner wall 132 of the outer tube 82, which restricts movement of the inner tube 84 relative to the outer tube 82. The cam lock assembly 86 moves from the unlocked position 128 to the locked position 130 by rotating the inner tube 84 in a first direction relative to the outer tube 82. As the inner tube 84 is twisted relative to the outer tube 82, the offset apertures 116, 120 cause the second cylinder 118 to move radially outward thereby increasingly making contact with the inner wall 132. The cam lock assembly moves from the locked position 130 to the unlocked position 128 by rotating the inner tube 84 in a second direction relative to the outer tube 82. As the inner tube 84 is twisted in the second direction relative to the outer tube 82, the offset apertures 116, 120 cause the second cylinder 118 to move radially inward thereby decreasing the amount of contact between the second cylinder 118 and the inner wall 132.

[0025] With reference to FIGS. 1-3 and 6-8, when assembled, the stabilizing member 20 is coupled to the adjustable shaft 80 by a spherical joint or ball-and-socket joint 150. The spherical joint 150 includes a first end 152 and a second end 154. The first end 152 is received in the aperture 34 in the connector 32 on the stabilizing member 20 and includes a socket 156 extending therefrom. The second end 154 is received in the through-hole 96 in the binding 94 disposed at the first end 90 of the outer tube 82 and includes a projection 158 extending therefrom. The projection 158, which has a spherical shape, is matingly received in the socket 156 for rotation therein. The spherical joint 150 allows the stabilizing member to freely rotate along at least three axes relative to the shaft about the longitudinal axis A of the jack 10.

[0026] Further with respect to FIGS. 1-8, the shaft assembly 80 is coupled to the foot assembly 50. The threaded shaft 66 is received within and adjustable relative to the inner tube 84. More specifically, the threaded shaft 66 is received within the threaded through-hole 108 of the binding 106 mounted at the second end 104 of the inner tube 84. As such, when assembled, the shaft assembly 80 is adjustable relative to the foot assembly 50 by rotating the outer tube 82, with the help of the grip 112, such that the inner tube 84 moves longitudinally along the threads of the threaded shaft 66. The threaded nut 69 secures the shaft 66 relative to the inner tube 84 such that once positioned, the screw joint is locked in place.

[0027] Referring to FIG. 10, in operation, the suction cup 26 of the stabilizing member 20 is attached to the glass panel 200, such as a windshield, for example. A length 202 of the shaft 80 is determined by the distance from the point of suction 204 to a fixed surface 206, such as a hood of a vehicle or on a windshield wiper post, for example. Thus, while the cam lock assembly 86 is unlocked such that the inner tube 84 is slidable along the length of the outer tube 82, the foot body 52 is placed against the fixed surface 206 to achieve the length of the shaft 66. Once the length 202 is achieved, the inner tube 84 is rotated in the first direction relative to the outer tube 82 thereby locking the inner tube 84 with the respect to the outer tube 82, as described above. The alignment of the windshield 200 is ensured because the screw joint created by the threaded shaft 66 allows for fine adjustments of the position of the windshield 200 during installation. Once installation is complete, the inner tube 84 is rotated in the second direction relative to the outer tube 82 thereby unlocking the cam locking mechanism 86. The retaining member 180, 180' attached to the windshield 200 once the cam locking mechanism 86 has locked the jack 10 into place. The retaining member 180, 180' limits side-to-side (i.e., motion to the left or right) of the shaft 80 about the spherical joint 150. However, as discussed above, the retaining member 180, 180' maintains adjustability of the shaft 80 such that it is moveable up, down, and by twisting to achieve further extension and/or retraction. Pulling the handle then releases the suction cup 26 from the windshield 200. As such, the assembled jack 10 is afforded significant adjustability to align, stabilize, and suspend panels of various dimensions. FIG. 10 also illustrates the use of the jack in conjunction with additional jacks to more easily manipulate and align glass panels relative to fixed surfaces.

[0028] In the illustrated embodiment, adjustability of the jack is achieved by the spherical joint between the stabilizing member and the adjustable shaft assembly, the cam locking mechanism included in the adjustable shaft and the threaded shaft that is received within the adjustable shaft assembly. It is contemplated that alternate embodiments may have other suitable types of mechanisms that ensure adjustability among the stabilizing member, adjustable shaft, and foot assembly.

[0029] Thus, the invention provides, among other things, a windshield replacement tool or jack that is adjustable to mount glass panels of various shapes and sizes.