Abstract: A method and apparatus for forming and mounting a sleeve and a thrust member in a bore in a motor/gear drive housing shaft to support the motor/gear drive shaft against radial and axial movement. Gates are formed in the motor/gear drive housing and communicate with separate first and second bores in the housing. A mold core is inserted into the housing and closes off one bore to allow the injection of molten plastic into a cavity formed between the tip end portion of the mold core and the first bore to form an annular sleeve. The annular sleeve has an inner diameter larger than the outer diameter of the end tip portion of the motor/gear drive shaft to be nominally spaced from the outer diameter of the drive shaft, but is supportingly engaged by the drive shaft under radial deformation of the drive shaft.

Abstract: A method and apparatus for forming and mounting a sleeve and a thrust member in a bore in a motor/gear drive housing shaft to support the motor/gear drive shaft against radial and axial movement. Gates are formed in the motor/gear drive housing and communicate with separate first and second bores in the housing. A mold core is inserted into the housing and closes off one bore to allow the injection of molten plastic into a cavity formed between the tip end portion of the mold core and the first bore to form an annular sleeve. The annular sleeve has an inner diameter larger than the outer diameter of the end tip portion of the motor/gear drive shaft to be nominally spaced from the outer diameter of the drive shaft, but is supportingly engaged by the drive shaft under radial deformation of the drive shaft.

Abstract: A windshield wiper drive apparatus includes a non-electrical contact position detector of the wiper inwipe position. A magnet is rotated by the wiper drive gear and moves past a magnetically responsive sensor mounted within the drive housing to detect the inwipe position of the wipers. In one aspect, a rotatable cam is mounted in the housing and carries the magnet. Interengaging members on the drive gear and the cam cause rotation of the cam in only the normal direction of rotation of the drive gear. Any back movement of the drive gear through interfering contact of the wiper blades with an obstruction separates the drive gear interengaging member from the cam preventing movement of the cam.

Abstract: A motor housing assembly includes a gearbox and a gearbox cover having a resilient elastomeric seal overmolded directly onto the cover. The substrate material of the first surface and the elastomeric material of the seal are molecularly compatible such that they will chemically bond at the molecular level, resulting in a fused, single-piece seal-substrate assembly.

Abstract: A method and apparatus for forming and mounting a sleeve and a thrust member in a bore in a motor/gear drive housing shaft to support the motor/gear drive shaft against radial and axial movement. Gates are formed in the motor/gear drive housing and communicate with separate first and second bores in the housing. A mold core is inserted into the housing and closes off one bore to allow the injection of molten plastic into a cavity formed between the tip end portion of the mold core and the first bore to form an annular sleeve. The annular sleeve has an inner diameter larger than the outer diameter of the end tip portion of the motor/gear drive shaft to be nominally spaced from the outer diameter of the drive shaft, but is supportingly engaged by the drive shaft under radial deformation of the drive shaft.

Abstract: A motor housing assembly includes a motor housing mounted to a gear housing and a brush holder assembly where the brush holder assembly is fixed in position by the junction between the motor housing and the gearbox. In one embodiment, a gasket is mechanically attached to the brush holder assembly via detents, and is compressed between the motor housing and gearbox when the two are assembled together.

Abstract: A variable length crank arm in a windshield wiper system provides a depressed park position for an associated wiper blade when the direction of rotation of a drive motor is reversed. The crank arm relies on an eccentric driver to vary its length between a first length and a longer second length. When the eccentric driver is rotated in a first direction to wipe the windshield, a spring loaded pin keeps the eccentric driver rotatably fixed to an output arm with the crank arm consequently at the first length. The spring loaded pin also engages a cam slot in a cam plate, the cam plate rotating freely with the output arm and the eccentric driver in the first direction. To move the blade to the depressed park position, the direction of rotation of the drive motor is reversed. This causes the cam plate to become rotatably stopped, with the now stationary cam slot forcing the pin out of engagement with the output arm.

Abstract: A variable length crank arm in a windshield wiper system provides a depressed park position for an associated wiper blade when the direction of rotation of a drive motor is reversed. The crank arm relies on an eccentric driver to vary its length and between a first length a longer second length. When the eccentric driver is rotated in a first direction to wipe the windshield, a spring loaded pin keeps the eccentric driver rotatably fixed to an output arm with the crank arm consequently at the first length. The spring loaded pin also engages a cam slot in a cam plate, the cam plate rotating freely with the output arm and the eccentric driver in the first direction. To move the blade to the depressed park position, the direction of rotation of the drive motor is reversed. This causes the cam plate to become rotatably stopped, with the now stationary cam slot forcing the pin out of engagement with the output arm.