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In the latter half of 2004, a new concept of window lift mechanism will be supplied to a major OEM for a high volume passenger car in the North American market. This new concept of window lift mechanism, marketed by Dura Automotive Systems, Inc. as the Racklift™, was jointly developed in conjunction with an independent inventor. The Rack Lift mechanism is essentially an all-plastic construction, which results in a very light weight unit. Plastic gears are driven along each side of an injection molded unitary dual rack providing a quiet and efficient operation. The higher efficiency of this mechanism, compared to traditional designs, allows use of smaller, lighter and lower output electric motors. The plastic mechanism is greaseless and thus produces a constant efficiency over the required operating temperature range. The combination of high efficiency, lightweight and robustness to temperature makes this an ideal concept for automotive applications.

Recently, samples of a PVC modular window were produced for a major North American OEM. This modular window included a roll formed swept metal division bar which was encapsulated along with a curved piece of tempered glass and one metal attachment stud. Initial samples met all criteria for dimensional, functional and cosmetic requirements. The success of the program can be attributed to analytical and experimental development work accomplished early in the program. This paper will review how results of analytical mold fill simulations, finite element analysis and experimental adhesion development were integrated into this product. Also, the key design criteria, tooling concepts, and process parameters will be discussed.