- Case Study 1 - Window Slides
Window Slides with plastic inserts connect to the window and slide up and down on the Regulator. The plastic inserts secure the cable ends in the Window Regulator Assembly. The plastic inserts in the window slide become brittle and crack from wear and temperature extremes. Breakage allows the cable ends to pull out and cause failure of the Window Regulator. Dorman replaced the original plastic with a nylon material, which improved the durability and eliminated the premature pull-out of the Window Regulator cable.
- Case Study 2 - Cable Guides
Cable guides secure the cable and allow movement of the cable with the motion of the Window Regulator when it is working. The cable guide design was previously a rectangular design that showed a propensity for breakage causing the cable to pull out. Dorman Engineers redesigned the rectangular cable end to a cylindrical design with a more robust material to prevent breakage. This design proved more durable in our Quality Validation process and maintained functionality.
- Case Study 3 - Mounting Brackets
Mounting Brackets secure the Window Regulator Assembly to the vehicle door. The Mounting Brackets were originally designed as a flat, stamped steel piece that had the tendency to bend under limited Regulator stress. Dorman not only replaced the original steel with a thicker, more durable metal, they also re-engineered the bracket in a rolled-edge design for additional strength. This allows this bracket to withstand greater wear stress than the original design.
- Case Study 4 - Metal Arms
Metal arms on a Scissor-Style Window Regulator Assembly. These metal arms were originally designed with 2.0mm steel and had the tendency to bend and twist under normal use. Dorman redesigned the metal arms with an improved grade of metal at an increased thickness to prevent the bending and twisting that was previously an issue with this Window Regulator style.