Mounting system, window assembly including the mounting system, and method of forming the window assembly

Abstract

To solve problems with the prior art.SOLUTION: A mounting system configured to support a component relative to a mounting surface of a vehicle includes a mounting bracket including a mounting portion configured to be coupled to the mounting surface of the vehicle. The mounting bracket defines a component receptacle configured to support the component. The mounting bracket comprises a first plastic material. The mounting system also includes a seal coupled to the mounting bracket and configured to engage the mounting surface of the vehicle to inhibit ingress of debris between the mounting portion and the mounting surface of the vehicle. The seal comprises a second plastic material different than the first plastic material. The mounting system may be included in a window assembly where the mounting surface of the vehicle is an inner surface of a transparent pane and the component is a sensor.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] (Reference to Related Application) This application claims priority to U.S. Patent Application No. 18 / 431,403, filed February 2, 2024, which is incorporated herein by reference in its entirety. This application also claims the benefit of U.S. Provisional Patent Application No. 63 / 443,580, filed February 6, 2023, which is incorporated herein by reference in its entirety.

[0002] (Technical field) FIELD OF THE INVENTION The present invention relates generally to a mounting system, a window assembly including a mounting system, and a method of forming a window assembly for a vehicle. [Background technology]

[0003] Conventional vehicle components (such as sensors) are mounted to various mounting surfaces of the vehicle, such as the windshield, pillars, etc. Such components can be sensitive to outside elements, such as water, dirt, and other debris. Furthermore, mounting these components to the windshield mounting surface can result in undesirable noise, vibration, and harshness (NVH). To this end, there remains a need for improved mounting systems for housing components, such as sensors, to mounting surfaces of the vehicle. Summary of the Invention

[0004] One general aspect of the present disclosure includes a mounting system configured to support a component against a mounting surface of a vehicle. The mounting system includes a mounting bracket including a mounting portion configured to be coupled to the mounting surface of the vehicle. The mounting bracket defines a component receptacle configured to support the component. The mounting bracket includes a first plastic material. The first plastic material includes a thermoplastic semi-crystalline polymer having at least one of a modulus of elasticity of 1000 MPa or greater and a Shore D hardness of 70 or greater. The mounting system includes a seal coupled to the mounting bracket and configured to engage the mounting surface of the vehicle to prevent ingress of debris between the mounting portion and the mounting surface of the vehicle. The seal includes a second plastic material different from the first plastic material. The second plastic material includes a thermoplastic elastomer having at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less. The mounting bracket is formed from a first injection molding operation, and the seal is formed from a second injection molding operation subsequent to the first injection molding operation such that the seal is overmolded onto the mounting bracket.

[0005] Another general aspect of the present disclosure includes a window assembly configured to accommodate a sensor. The window assembly includes a transparent pane having an inner surface and an opposing outer surface. The window assembly also includes a mounting bracket including a mounting portion coupled to the inner surface of the transparent pane. The mounting portion defines a total mounting area bounded by the perimeter of the mounting portion. The mounting bracket also defines a sensor opening within the perimeter of the mounting portion. The mounting bracket includes a first plastic material having at least one of a modulus of elasticity of 1000 MPa or greater and a Shore D hardness of 70 or greater. The mounting bracket is configured to support the sensor such that the sensor is aligned with the sensor opening. The window assembly also includes a seal coupled to the mounting bracket along the perimeter of the mounting portion and engaging the inner surface of the transparent pane to prevent the ingress of debris between the mounting portion and the inner surface of the transparent pane. The seal includes a second plastic material different from the first plastic material. The second plastic material has at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less.

[0006] A further general aspect of the present disclosure includes a method of forming a window assembly configured to accommodate one or more sensors. The method includes providing a transparent pane having an inner surface and an opposing outer surface. The method also includes forming a mounting bracket having a mounting portion, the mounting portion defining a total mounting area bounded by a perimeter of the mounting portion and defining a sensor opening within the perimeter of the mounting portion. The mounting bracket includes a first plastic material having at least one of a modulus of elasticity of 1000 MPa or greater and a Shore D hardness of 70 or greater. The mounting bracket is configured to support the sensor such that the sensor is aligned with the sensor opening. The method also includes coupling a seal to the mounting bracket along the perimeter of the mounting portion. The seal includes a second plastic material different from the first plastic material. The second plastic material has at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less. The method also includes coupling the mounting bracket to the inner surface of the transparent pane such that the seal engages the inner surface of the transparent pane to prevent the ingress of debris between the mounting portion and the inner surface of the transparent pane.

[0007] Other advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a front schematic view of a mounting system according to the present disclosure.

[0009] [Figure 2A] 1 is a cross-sectional view of an example of a mounting system according to the present disclosure.

[0010] [Figure 2B] FIG. 10 is a cross-sectional view of another example of a mounting system according to the present disclosure.

[0011] [Figure 3]FIG. 1 is a front view of yet another example of a mounting system according to the present disclosure configured to be coupled to a window assembly of a vehicle, the mounting system including a mounting bracket, and the window assembly including a transparent window pane.

[0012] [Figure 4] FIG. 4 is a plan view of the mounting system of FIG. 3 shown installed in a window assembly coupled to a vehicle.

[0013] [Figure 5] 5 is a schematic cross-sectional view of the mounting system and window assembly of FIGS. 3 and 4 taken along line 5-5 of FIG. 4.

[0014] [Figure 6] 5 is an enlarged view of the mounting system of FIGS. 3 and 4, the mounting system further including a cover.

[0015] [Figure 7] FIG. 7 is a cross-sectional view of the mounting system of FIG. 6.

[0016] [Figure 8] FIG. 7 is a perspective view of the mounting system and window assembly of FIG. 6.

[0017] [Figure 9] 7 is a cross-sectional view of the mounting system of FIG. 6, the mounting system including a second seal interposed between the mounting bracket and the cover.

[0018] [Figure 10] 10 is a bottom cross-sectional view of the mounting system of FIG. 9 showing one configuration of the first seal and the second seal.

[0019] [Figure 11] 10 is a bottom cross-sectional view of the mounting system of FIG. 9 showing an alternative configuration of the first seal and the second seal.

[0020] [Figure 12] FIG. 1 is a perspective view of another mounting system according to the present disclosure.

[0021] [Figure 13] 13 is a perspective view of the mounting system of FIG. 12, the mounting system including a mounting bracket having a mounting portion, the mounting portion configured to be coupled to an outer cover.

[0022] [Figure 14] 15 is a cross-sectional view of the mounting system of FIGS. 12 and 13 taken along line 15-15 of FIG. 13.

[0023] [Figure 15] 1 is a flowchart illustrating a method of forming a mounting system according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0024] With reference to the figures, in which like numerals indicate like parts throughout the several views, various configurations of mounting systems 100, 200, 300 according to the present disclosure are generally shown. The mounting systems 100, 200, 300 according to the present disclosure are configured to support a component 101 relative to a mounting surface 104 of a vehicle 108. The component 101 may be a sensor (such as a camera), a display panel, other vehicle components (such as an interior panel, a roof panel, a body panel, etc.), and the like, or a combination thereof. As described in more detail below, the mounting system 100 may be configured to support more than one component 101 relative to the mounting surface 104.

[0025] 1-2B, a mounting system 100 according to the present disclosure includes a mounting bracket 114. The mounting bracket 114 is constructed from a first plastic material. In these embodiments, the first plastic material comprises a thermoplastic semi-crystalline polymer. Additionally, the first plastic material according to these embodiments has at least one of a modulus of elasticity of 1000 MPa or greater and a Shore D hardness of 70 or greater. In other words, the first plastic material can have only a modulus of elasticity of 1000 MPa or greater, only a Shore D hardness of 70 or greater, or both a modulus of elasticity of 1000 MPa or greater and a Shore D hardness of 70 or greater.

[0026] In some instances, the first plastic material has a modulus of elasticity between 1000 MPa and 10,000 MPa. For example, the modulus of elasticity of the first plastic material can be between 1000 MPa and 2000 MPa, between 2000 MPa and 3000 MPa, between 3000 MPa and 4000 MPa, between 4000 MPa and 5000 MPa, between 5000 MPa and 6000 MPa, between 6000 MPa and 7000 MPa, between 7000 MPa and 8000 MPa, between 8000 MPa and 9000 MPa, and between 9000 MPa and 10,000 MPa. In instances where the first plastic material is reinforced with additional materials (discussed below), the resulting modulus of elasticity can be significantly higher (e.g., as high as 200,000 MPa). One suitable technique for measuring elastic modulus is provided in ASTM D638(2022), which is entitled "Standard Test Methods for Tensile Properties of Plastics," and is incorporated by reference in its entirety. Another suitable technique for measuring elastic modulus is provided in ASTM D790(2017), which is entitled "Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials," and is incorporated by reference in its entirety.

[0027] In some examples, the first plastic material has a Shore D hardness between 70 and 100. For example, the Shore D hardness of the first plastic material may be between 70 and 75, between 75 and 80, between 80 and 85, between 85 and 90, between 90 and 95, and between 95 and 100. One suitable technique for measuring Shore A / D hardness is provided in ASTM D2240(2021), which is entitled "Standard Test Method for Rubber Property Durometer Hardness," and is incorporated by reference in its entirety.

[0028] In some examples, the first plastic material is selected from the group consisting of polybutylene terephthalate and polycaprolactam (i.e., PA6 nylon), although other materials are contemplated. It should also be understood that in some examples, the first plastic material may be reinforced with additional materials such as carbon fiber or glass fiber.

[0029] The size and shape of the mounting bracket 114 are not particularly limited for purposes of this disclosure. Accordingly, the mounting bracket is shown schematically in FIGS. 1-2B . The mounting bracket 114 has a mounting portion 116 configured to be coupled (e.g., via an adhesive) to the mounting surface 104 of the vehicle 108. It should be understood that the mounting portion 116 may be coupled to the mounting surface 104 of the vehicle 108 directly or indirectly (e.g., using an intermediate component between the mounting portion 116 and the mounting surface 104). The mounting portion 116 may define an overall mounting area 118 bounded by a perimeter 120 of the mounting portion 116.

[0030] 1-2B , mounting portion 116 defines one or more component receptacles 121 that may be disposed within a perimeter 120 of mounting portion 116. Mounting bracket 114 is configured to support component 101 such that component 101 is configured to be at least partially disposed within each component receptacle 121. Component 101 is typically removably coupled to mounting bracket 114. For example, component 101 may be fixed to mounting bracket 114 (e.g., via screws, clips, etc.), or component 101 may be disposed within component receptacle 121 via an interference fit. Other configurations for coupling component 101 to mounting bracket 114 are envisioned.

[0031] 2A , the mounting surface 104 is a transparent pane 106 of a vehicle 108. Here, the mounting system 100 is configured to support the component 101 against the transparent pane 106 of the vehicle 108. Specifically, the mounting bracket 114 is configured to be coupled to the mounting surface 104 defined by the transparent pane 106 to support the component 101. In the illustrated example, the component 101 is a sensor 102 (described below). Here, the mounting bracket 114 supports the sensor 102 such that the field of view (FOV) of the sensor 102 faces the transparent pane 106 (and thus the sensor 102 looks through the transparent pane 106). In this example, the component receptacle 121 is further defined as a sensor aperture 122 extending through the mounting bracket 114 and defines a sensor area 130 bounded by a sensor aperture perimeter 132, the sensor area 130 being smaller than the total mounting area 118 of the mounting portion 116. In some examples, the sensor aperture 122 is spaced from the perimeter 120 of the mounting portion 116 (i.e., a portion of the total mounting area 118 is disposed between the sensor aperture 122 and the perimeter 120 of the mounting portion 116). In the example of FIG. 2B , the mounting surface 104 may be a sheet metal surface of the vehicle 108. Here, the mounting bracket 114 is configured to couple to the mounting surface 104 defined by the transparent window glass 106 and support the component 101 against the mounting surface 104.

[0032] In configurations in which the mounting system 100 is configured to support more than one component 101, the mounting bracket 114 defines a plurality of component receptacles 121 configured to support respective components 101. It should be understood that the mounting system 100 may be configured to support any number of components 101, such as two, three, four, five, six, or more components 101. In some examples, a single component receptacle 121 may be configured to support multiple components 101.

[0033] As best shown in FIGS. 2A and 2B , the mounting system 100 also includes a seal 126. The seal 126 is composed of a second plastic material that is different from the first plastic material of the mounting bracket 114. In these embodiments, the second plastic material comprises a thermoplastic elastomer. In some examples, the thermoplastic elastomer is further defined as a thermoplastic urethane, although other materials are contemplated. Additionally, the second plastic material according to these embodiments has at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less. In other words, the second plastic material can have only a modulus of elasticity of 50 MPa or less, only a Shore A hardness of 80 or less, or both a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less. In some examples, the second plastic material has a modulus of elasticity between greater than 0 MPa and less than or equal to 50 MPa. For example, the elastic modulus of the second plastic material may be between greater than 0 MPa and 50 MPa, between greater than 0 MPa and 40 MPa, between greater than 0 MPa and 30 MPa, between greater than 0 MPa and 20 MPa, between greater than 0 MPa and 10 MPa, or between greater than 0 MPa and 5 MPa. In some examples, the second plastic material has a Shore A hardness of between 0 and 80. For example, the Shore A hardness of the second plastic material may be between 0 and 80, between 0 and 70, between 0 and 60, between 0 and 50, between 0 and 40, between 0 and 30, between 0 and 20, and between 0 and 10.

[0034] As best shown in FIGS. 2A and 2B , the seal 126 is coupled to the mounting bracket 114. Here, the seal 126 extends away from the mounting portion 116 such that the seal 126 is configured to engage the mounting surface 104 to prevent the ingress of debris, dust, moisture, etc., in the space between the mounting surface 104 and the mounting bracket 114 (e.g., the entire mounting area 118 of the mounting portion 116). The seal 126 extends along the perimeter 120 of the mounting portion 116 of the mounting bracket 114 (best shown in FIG. 1 ). It should be understood that in some embodiments, such as that shown in FIG. 1 , the seal 126 extends along the entire perimeter 120 of the mounting portion 116 of the mounting bracket 114. However, in other embodiments, the seal 126 may extend partially along the perimeter 120 (e.g., on one side) of the mounting portion 116 of the mounting bracket 114. In addition to preventing the intrusion of debris, dust, moisture, etc. in the space between the mounting surface 104 and the mounting bracket 114, having the seal 126 configured to engage the mounting surface 104 also reduces vibrations between the mounting bracket 114 and the mounting surface 104, and also reduces noise, vibration, and harshness (NVH) that may occur between the mounting bracket 114 and the mounting surface 104 of the vehicle 108.

[0035] Various approaches for coupling the seal 126 to the mounting bracket 114 are contemplated. For example, the seal 126 may be overmolded onto the mounting bracket 114. The mounting bracket 114 and the seal 126 may be formed through two-shot injection molding. Specifically, the mounting bracket 114 may be injection molded with a first plastic material, and then the seal 126, including a second plastic material, may be injection molded onto the mounting bracket 114. In other words, the mounting bracket 114 may be formed from a first injection molding operation, and the seal 126 may be formed from a second injection molding operation subsequent to the first injection molding operation, such that the seal 126 is overmolded onto the mounting bracket 114. In these examples, it is important to select the first and second plastic materials to be compatible with the overmolding process. In some examples, such as that shown in FIG. 2A, the mounting bracket 114 defines a bracket channel 128. In some examples, the seal 126 is at least partially disposed within the bracket channel 128. For example, the seal 126 may be overmolded or press-fit within the bracket channel 128 to couple the seal 126 to the mounting bracket 114. Other configurations for coupling the seal 126 to the mounting bracket 114 are envisioned.

[0036] 2A and 2B, the mounting system 100 may further include a cover 134 coupled to the mounting bracket 114. Although not required, the cover 134 may conceal the component 101. The cover 134 may be fastened to the mounting bracket 114 (e.g., via screws, clips, etc.), or the cover 134 may be coupled to the mounting bracket 114 via an interference fit. Other configurations for coupling the cover 134 to the mounting bracket 114 are envisioned. If present, the cover 134 extends away from the mounting surface 104 when coupled to the mounting bracket 114. For example, with reference to FIG. 2A, in a configuration in which the mounting bracket 114 is coupled to the transparent window pane 106, the mounting bracket 114 is positioned between the transparent window pane 106 and the cover 134. In another example, with reference to FIG. 2B, the mounting bracket 114 may be positioned between the cover 134 and the mounting surface 104 of the vehicle 108, such as sheet metal. The cover 134 is typically called a beauty cover or applique.

[0037] 3-11 , a mounting system 200 according to the present disclosure is configured to receive a sensor 202 relative to a mounting surface 204 (e.g., an inner surface 205 of a transparent window glass 206 of a vehicle 108). In these examples, the mounting system 200 may be referred to as a "sensor mounting system 200." The sensor 202 may be a camera, a rain sensor, a light sensor, a light detection and ranging (LIDAR) sensor, a crash sensor, a forward crash sensor, or the like, or a combination thereof. As described in more detail below, the sensor mounting system 200 may have more than one sensor 202.

[0038] In examples where the mounting surface 204 of the vehicle 108 is the interior surface 205 of a transparent window glass 206 of the vehicle 208, the sensor mounting system 200 and the transparent window glass 206 collectively define a window assembly 212. In some examples, the transparent window glass 206 is implemented as at least one pane of glass. When the transparent window glass 206 is implemented as glass, the transparent window glass 206 is composed of any suitable glass composition, including, but not limited to, soda-lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, etc. Those skilled in the art will recognize that the transparent window glass 206 may be formed from a polymeric material, such as polymethylmethacrylate, polycarbonate, polyvinyl butyral, etc.

[0039] The transparent window glass 206 has a thickness T1. The thickness T1 of the transparent window glass 206 may be from about 0.3 mm to about 4.1 mm. More specifically, the thickness T1 can be about 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm, 3.9 mm, 4.0 mm, or 4.1 mm.

[0040] As used herein, the term "transparent" refers to a material that allows 70% or more of the light transmission within a predetermined visible light range to pass through. Typically, the predetermined visible light range is the segment of the electromagnetic spectrum that is visible to the human eye (i.e., visible light). Thus, the predetermined visible light range typically refers to wavelengths of light from about 380 to about 780 nanometers. However, if the sensor 202 is a LIDAR sensor, the transparent window glass 206 may additionally or alternatively allow 70% or more of the light transmission within the predetermined visible light range corresponding to the operating spectrum of the LIDAR sensor to pass through. For example, the predetermined visible light range corresponding to the operating spectrum of the LIDAR sensor may be between 780 nanometers and 2000 nanometers. Other spectrums are contemplated.

[0041] In some examples, as best shown in FIG. 5 , the transparent window glass 206 is formed as a laminated glazing, such as a windshield. In these examples, the laminated transparent window glass 206 includes an inner glass substrate 206A defining an inner surface 205, an outer glass substrate 206B defining an outer surface 210, and a polymer interlayer 206C disposed between the inner and outer glass substrates 206A and 206B. The inner and outer glass substrates 206A and 206B may be composed of any suitable glass composition, including, but not limited to, soda-lime glass, aluminosilicate glass, borosilicate glass, boroaluminosilicate glass, and the like. It should be understood that the inner and outer glass substrates 206A and 206B may be composed of the same or different glass compositions.

[0042] The inner glass substrate 206A may have a thickness TA, and the outer glass substrate 206B may have a thickness TB. The thickness TA of the inner glass substrate 206A and the thickness TB of the outer glass substrate 206B may each be any thickness suitable for the application. For example, the thickness TA of the inner glass substrate 206A and the thickness TB of the outer glass substrate 206B may each be approximately 0.3 mm to approximately 4.1 mm. More specifically, the thicknesses TA and TB may be about 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm, 3.9 mm, 4.0 mm, or 4.1 mm, respectively. It should be understood that the thicknesses TA and TB may be the same or different. In one example, the inner glass substrate 206A and the outer glass substrate 206B have the same thickness (i.e., TA is equal to TB) such that the clear window pane 206 is considered a "symmetric" stack. However, in another example, the inner glass substrate 206A and the outer glass substrate 206B have different thicknesses (i.e., TA is not equal to TB) such that the clear window pane 206 is considered an "asymmetric" stack. All combinations of the exemplary TA and TB values ​​listed above, and all fractional values ​​therebetween, are contemplated.

[0043] The polymeric interlayer 206C bonds the inner and outer glass substrates 206A and 206B together such that the polymeric interlayer 206C retains the inner and / or outer glass substrates 206A and 206B in the event of impact or breakage of the transparent window pane 206. The polymeric interlayer 206C comprises a polymer or thermoplastic, such as polyvinyl butyral (PVB), ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), or the like. Other suitable materials for implementing the polymeric interlayer 206C that provide the desired performance characteristics related to optical haze, adhesion to glass, and structural rigidity are utilized. Like the inner and outer glass substrates 206A and 206B, the polymeric interlayer 206C is substantially transparent to light or otherwise transparent.

[0044] 3-5 , the sensor mounting system 200 includes a mounting bracket 214. The mounting bracket 214 is constructed from a first plastic material. In these embodiments, the first plastic material may have a modulus of elasticity of 1000 MPa or greater. The first plastic material may additionally or alternatively have a Shore D hardness of 70 or greater. In some examples, the first plastic material is a thermoplastic semi-crystalline polymer that may be selected from the group consisting of polybutylene terephthalate and polycaprolactam (i.e., PA6 nylon), although other materials are contemplated. The mounting bracket 214 has a mounting portion 216 configured to be coupled to a mounting surface 204 of the vehicle 108 (e.g., the inner surface 205 of the transparent window glass 206). It should be understood that the mounting portion 216 may be coupled to the mounting surface 204 of the vehicle 208 directly or indirectly (e.g., using an intermediate component between the mounting portion 216 and the mounting surface 204). For example, the mounting portion 216 may be bonded directly to the mounting surface 204 with an adhesive, or in other examples, an intermediate component may be bonded to the mounting surface 204 and the mounting portion 216 may be bonded to the intermediate component. The mounting portion 216 defines an overall mounting area 218 bounded by a perimeter 220 of the mounting portion 216.

[0045] 3-5 , mounting portion 216 defines one or more sensor openings 222 within a perimeter 220 of mounting portion 216. Mounting bracket 214 is configured to support sensor 202 such that sensor 202 is aligned with its respective sensor opening 222. For example, as best shown in FIG. 5 , in a configuration in which sensor mounting system 200 is included in window assembly 212, the mounting bracket supports sensor 202 such that the field of view (FOV) of sensor 202 faces (and thus the sensor 202 looks through) the transparent window pane 206. Sensor 202 is typically removably coupled to mounting bracket 214. For example, sensor 202 may be fastened to mounting bracket 214 (e.g., via screws, clips, etc.), or sensor 202 may be positioned within sensor opening 222 via an interference fit. Other configurations for coupling sensor 202 to mounting bracket 214 are envisioned.

[0046] In some examples, the sensor opening 222 defines a sensor area 230 bounded by a sensor opening perimeter 232, the sensor area 230 being smaller than the total mounting area 218 of the mounting portion 216. In some examples, the sensor opening 222 is spaced from the perimeter 220 of the mounting portion 216 (i.e., a portion of the total mounting area 218 is disposed between the sensor opening 222 and the perimeter 220 of the mounting portion 216). It should be understood that in addition to the seal 226 described below, the sensor mounting system 200 may further include a sensor perimeter seal coupled to the mounting bracket 214, constructed from a second plastic material (described below), and configured to engage the mounting surface 204 to prevent debris, dust, moisture, and the like from entering the sensor opening 222.

[0047] In configurations in which sensor mounting system 200 is configured to support more than one sensor 202, mounting bracket 214 defines multiple sensor openings 222 configured to support each sensor 202 such that the sensor 202 is concealed within the confines of seal 226 (described below). It should be understood that sensor mounting system 200 may be configured to support any number of sensors 202, such as two, three, four, five, six, or more sensors 202. For example, mounting portion 216 may define a first sensor opening to accommodate a camera, a second sensor opening to accommodate a rain sensor, a third opening to accommodate a light sensor, and a fourth opening to accommodate a LIDAR sensor. In some examples, a single sensor opening 222 may be configured to support multiple sensors 202. Additionally, in configurations in which the sensor mounting system 200 is included in a window assembly 212, the mounting portion 216 defines a notch 224 sized to receive a mirror button for securing a rearview mirror 225 to the transparent window glass 206.

[0048] The sensor mounting system 200 also includes a seal 226. The seal 226 is composed of a second plastic material that is different from the first plastic material of the mounting bracket 214. In these embodiments, the second plastic material has a modulus of elasticity of 50 MPa or less. The second plastic material may additionally or alternatively have a Shore A hardness of 80 or less. In some examples, the second plastic material is a thermoplastic elastomer, which may be further defined as a thermoplastic urethane, although other materials are contemplated.

[0049] As best shown in FIG. 5 , the seal 226 is coupled to the mounting bracket 214. Here, the seal 226 extends away from the mounting portion 216 such that the seal 226 is configured to engage the mounting surface 204 (e.g., the inner surface 205 of the transparent window glass 206) to prevent the ingress of debris, dust, moisture, etc. in the space between the mounting surface 204 and the mounting bracket 214 (e.g., the entire mounting area 218 of the mounting portion 216). The seal 226 extends along the perimeter 220 of the mounting portion 216 of the mounting bracket 214 (best shown in FIG. 3 ). It should be understood that in some embodiments, such as that shown in FIG. 3 , the seal 226 extends along the entire perimeter 220 of the mounting portion 216 of the mounting bracket 214. However, in other embodiments, the seal 226 may extend partially along the perimeter 120 (e.g., on one side) of the mounting portion 216 of the mounting bracket 214. Configuring seal 226 to extend along perimeter 220 of mounting portion 216 and engage mounting surface 204 not only prevents debris, dust, moisture, and the like from entering the entire mounting area 218, but also prevents them from entering sensor opening 222. Additionally, configuring seal 226 to engage mounting surface 204 reduces vibrations between mounting bracket 214 and mounting surface 204, which also reduces noise, vibration, and harshness (NVH) that may occur between mounting bracket 214 and mounting surface 204 of vehicle 208.

[0050] Various approaches for coupling the seal 226 to the mounting bracket 214 are contemplated. For example, the seal 226 may be overmolded onto the mounting bracket 214. The mounting bracket 214 and the seal 226 may be formed through two-shot injection molding. Specifically, the mounting bracket 214 may be injection molded with a first plastic material, and then the seal 226, comprising a second plastic material, may be injection molded onto the mounting bracket 214. In other words, the mounting bracket 214 may be formed from a first injection molding operation, and the seal 226 may be formed from a second injection molding operation subsequent to the first injection molding operation, such that the seal 226 is overmolded onto the mounting bracket 214. In these examples, it is important to select the first and second plastic materials to be compatible with the overmolding process. In some examples, such as that shown in FIG. 5, the mounting bracket 214 defines a bracket channel 228. In some examples, the seal 226 is at least partially disposed within the bracket channel 228. For example, the seal 226 may be overmolded within the bracket channel 228 or may be press-fit within the bracket channel 228 to couple the seal 226 to the mounting bracket 214. Other configurations for coupling the seal 226 to the mounting bracket 214 are envisioned.

[0051] 5-11, the sensor mounting system 200 may further include a cover 234 coupled to the mounting bracket 214. Although not required, the cover 234 may conceal the sensor 202. The cover 234 may be fastened to the mounting bracket 214 (e.g., via screws, clips, etc.), or the cover 234 may be coupled to the mounting bracket 214 via an interference fit. Other configurations for coupling the cover 234 to the mounting bracket 214 are envisioned. If present, the cover 234 extends away from the mounting surface 204 when coupled to the mounting bracket 214. For example, with reference to FIG. 7, in a configuration in which the sensor mounting system 200 is included in a window assembly 212, the mounting bracket 214 is positioned between the inner surface 205 of the transparent window glass 206 and the cover 234. The cover 234 is typically referred to as a cosmetic cover. As shown in the illustrated configuration, when the sensor mounting system 200 is included in a window assembly 212 , the cover 234 may define a through-hole 235 that supports the rearview mirror 225 .

[0052] In one embodiment, the seal 226 is further defined as a first seal 226, and the sensor mounting system 200 may include a second seal 236. The second seal 236 is interposed between the mounting bracket 214 and the cover 234, as shown in FIGS. 10 and 11 . In other words, the second seal 236 is coupled to one of the mounting bracket 214 and the cover 234 and configured to abut against the other of the mounting bracket 214 and the cover 234 to prevent debris, dust, moisture, and the like from entering therebetween. The second seal 236, like the first seal 226, may be formed from a second plastic material. Various approaches are contemplated for coupling the second seal 236 to one of the mounting bracket 214 and the cover 234. 10 and 11, the mounting bracket 214 may have a mating portion 238 facing away from the mounting portion 216, and the second seal 236 may be disposed around a periphery 240 of the mating portion 238. In other examples, the second seal 236 is overmolded onto one of the mounting bracket 214 and the cover 234.

[0053] In another embodiment, another mounting system 300 according to the present disclosure is generally shown in FIGS. 12-14. Similar to the sensor mounting system 200 described above in the context of FIGS. 5-11, the sensor mounting system 300 is configured to accommodate a sensor 302 relative to a mounting surface 304 of a vehicle 308. Here, the mounting system 300 may also be referred to as a "sensor mounting system 300." In these examples, the mounting surface 304 of the vehicle 308 includes a pillar of the vehicle 308, such as an A-pillar, a B-pillar, or a C-pillar, or another pillar on the exterior of the vehicle. Similar to the sensor 202 described above in the context of FIGS. 5-11, the sensor 302 may be a camera, a rain sensor, a light sensor, a light detection and ranging (LIDAR) sensor, a crash sensor, a forward crash sensor, or the like, or a combination thereof, and the sensor mounting system 300 may include more than one sensor 302.

[0054] 12-14 , sensor mounting system 300 includes a mounting bracket 314 constructed from a first plastic material (described above). Mounting bracket 314 has a mounting portion 316 configured to be coupled to a mounting surface 304 of a vehicle 308, such as the vehicle's sheet metal, and / or to material behind an A-pillar, B-pillar, C-pillar, etc. Mounting portion 316 defines an overall mounting area 318 bounded by a perimeter 320 of mounting portion 316. Similar to what was described above in the context of FIGS. 5-11 , mounting portion 316 defines one or more sensor openings 322 within perimeter 320 of mounting portion 316. Mounting bracket 314 is configured to support sensors 302 such that sensors 302 are aligned with their respective sensor openings 322. Sensors 302 are typically removably coupled to mounting bracket 314. For example, the sensor 302 may be fastened to the mounting bracket 314 (e.g., via screws, clips, etc.), or the sensor 302 may be positioned within the sensor opening 322 via an interference fit. Other configurations for coupling the sensor 302 to the mounting bracket 314 are envisioned.

[0055] The sensor mounting system 300 also includes a seal 326 constructed from a second plastic material (described above). As discussed above in the context of Figures 5-11, various approaches are contemplated for coupling the seal 326 to the mounting bracket 314. For example, similar to that discussed above in the context of Figures 5-11, the mounting bracket 314 may define a bracket channel (not shown) for receiving the seal 326.

[0056] In this configuration, seal 326 extends away from mounting portion 316 such that seal 326 is configured to engage mounting surface 304 of vehicle 308 (e.g., the sheet metal of vehicle 308 and / or material behind the A-pillars, B-pillars, C-pillars, etc.) to prevent the ingress of debris, dust, moisture, etc. in the space between mounting surface 304 and mounting bracket 314. Configuring seal 326 to engage mounting surface 304 of vehicle 308 to prevent the ingress of debris between mounting portion 316 and mounting surface 304 of vehicle 308 not only prevents debris from entering the space between mounting surface 304 and mounting bracket 314, but also prevents debris from entering sensor opening 322.

[0057] 13 and 14 , similar to that described above in the context of FIGS. 5-11 , the sensor mounting system 300 may also include an exterior cover 334. FIG. 13 shows the mounting bracket 314 rotated approximately 180 degrees from the perspective of FIG. 12 . In other words, the mounting portion 316 shown in FIG. 12 is coupled to the mounting surface 304 of the vehicle 308, the exterior cover 334 faces the exterior of the vehicle 308, and the sensor 302 views the outside of the vehicle 308 through the exterior cover 334 (shown diagrammatically with reference numeral 330). In some examples, at least the portion 330 of the exterior cover 334 aligned with the field of view (FOV) of the sensor 302 may be transparent. In these examples, the exterior cover 334 may comprise glass or a transparent polymer material, as described above in the context of the transparent window pane 206. The outer cover 334 may include an opaque mask 332 disposed on portions of the outer cover 334 that are not aligned with the field of view FOV of the sensor 302 to hide any components underneath the outer cover 334 .

[0058] The present disclosure is also directed to a method 400 of forming a window assembly 212 according to the present disclosure. Referring to FIG. 15 , the method 400 includes step 402 of providing a transparent window pane 206 having an inner surface 205 and an opposing outer surface 210. The method 400 of forming the window assembly 212 also includes step 404 of forming a mounting bracket 214 having a mounting portion 216, the mounting portion 216 defining an overall mounting area 218 bounded by a perimeter 220 of the mounting portion 216. The mounting portion 216 further defines a sensor opening 222 within the perimeter 220 of the mounting portion 216. As described above, the mounting bracket 214 is constructed from a first plastic material having at least one of a modulus of elasticity of 1000 MPa or greater and a Shore D hardness of 80 or greater. The method 400 further includes step 406 of bonding a seal 226 to the mounting bracket 214 along the perimeter 220 of the mounting portion 216. Similar to above, seal 226 is comprised of a second plastic material different from the first plastic material, the second plastic material having at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less. In some examples, step 406 may further include overmolding seal 226 onto mounting bracket 214 along perimeter 220 of mounting portion 216. Method 400 additionally includes step 408 of bonding mounting bracket 214 to inner surface 205 of transparent window pane 206 (e.g., directly or indirectly via an adhesive) such that seal 226 engages inner surface 205 of transparent window pane 206 to prevent the ingress of debris between mounting portion 216 and inner surface 205 of transparent window pane 206.

[0059] Several embodiments have been set forth in the foregoing description. However, the embodiments described herein are not intended to be exhaustive or to limit the invention to the particular forms. The terminology that has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.

[0060] Various additional modifications and variations may be made to the above-described embodiments beyond those already described herein. This disclosure is presented for illustrative purposes and should not be construed as an exhaustive description of all embodiments or to limit the scope of the claims to the specific elements shown or described in connection with these embodiments. For example, but not limited to, any individual element of the described embodiments may be replaced with an alternative element that provides substantially similar functionality or otherwise provides appropriate operation. This includes, for example, currently known alternative elements, such as those currently known to those of ordinary skill in the art, and alternative elements that may be developed in the future, such as those that those of ordinary skill in the art will recognize as alternatives after they are developed. Any reference to a claim element in the singular, for example, using the articles “a,” “an,” “the,” or “said,” should not be construed as limiting that element to the singular. It will be further understood that the terms “include,” “includes,” and “including” have the same meaning as the terms “comprise,” “comprises,” and “comprising.”

[0061] The present disclosure also includes the following clauses, having specific features set forth in the dependent clauses, which may be specifically implemented as described in more detail above with reference to the configurations and drawings. Terms Article I. 1. A window assembly configured to house a sensor, comprising: a transparent pane including an interior surface and an opposing exterior surface; a mounting bracket including a mounting portion coupled to the inner surface of the transparent window pane, the mounting portion defining an overall mounting area bounded by a perimeter of the mounting portion and defining a sensor opening within the perimeter of the mounting portion, the mounting bracket comprising a first plastic material having at least one of a modulus of elasticity greater than or equal to 1000 MPa and a Shore D hardness greater than or equal to 70, the mounting bracket configured to support the sensor such that the sensor is aligned with the sensor opening; a seal coupled to the mounting bracket along the periphery of the mounting portion and engaging the inner surface of the transparent window pane to prevent the ingress of debris between the mounting portion and the inner surface of the transparent window pane, the seal comprising a second plastic material different from the first plastic material and having at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less; Window assembly. Article II. The window assembly of clause I, wherein the mounting bracket defines a bracket channel, and the seal is at least partially disposed within the bracket channel. Article III. The window assembly of clause I or II, further comprising a cover coupled to the mounting bracket to conceal the sensor. Article IV. The window assembly of clause III, wherein the seal is further defined as a first seal, and the window assembly further includes a second seal interposed between the mounting bracket and the cover to prevent the ingress of debris between the mounting bracket and the cover. Article V. the mounting bracket further includes a coupling portion facing opposite the mounting portion; the second seal is disposed around a periphery of the coupling portion; Window assemblies as described in Article IV Article VI. The window assembly of any one of clauses I-V, wherein the mounting bracket defines a notch configured to receive a vehicle rearview mirror. Article VII. The window assembly of any one of clauses I-VI, wherein the first plastic material is a thermoplastic semi-crystalline polymer. Article VIII. The window assembly of any one of clauses I-VI, wherein the first plastic material is selected from the group consisting of polybutylene terephthalate and polycaprolactam. Article IX. The window assembly of any one of clauses I-VIII, wherein the second plastic material is a thermoplastic elastomer. Article X. The window assembly of clause IX, wherein the thermoplastic elastomer is a thermoplastic urethane. Article XI. 1. A method of forming a window assembly configured to house one or more sensors, comprising: providing a transparent window pane having an inner surface and an opposing outer surface; forming a mounting bracket having a mounting portion defining a total mounting area bounded by a perimeter of the mounting portion and defining a sensor opening within the perimeter of the mounting portion, the mounting bracket comprising a first plastic material having at least one of a modulus of elasticity greater than or equal to 1000 MPa and a Shore D hardness greater than or equal to 70, the mounting bracket configured to support the sensor such that the sensor is aligned with the sensor opening; coupling a seal to the mounting bracket along the periphery of the mounting portion, the seal comprising a second plastic material different from the first plastic material and having at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less; and coupling the mounting bracket to the inner surface of the transparent window pane such that the seal engages the inner surface of the transparent window pane to prevent the ingress of debris between the mounting portion and the inner surface of the transparent window pane. method. Article XII. The method of clause XI, wherein coupling the seal to the mounting bracket further comprises overmolding the seal onto the mounting bracket along the perimeter of the mounting portion. Article XIII. 1. A mounting system configured to support a component relative to a mounting surface of a vehicle, comprising: a mounting bracket including a mounting portion configured to be coupled to the mounting surface of the vehicle, the mounting bracket defining a component receptacle configured to support the component, the mounting bracket including a first plastic material, the first plastic material including a thermoplastic semi-crystalline polymer having at least one of a modulus of elasticity of 1000 MPa or greater and a Shore D hardness of 70 or greater; a seal coupled to the mounting bracket and configured to engage the mounting surface of the vehicle to prevent ingress of debris between the mounting portion and the mounting surface of the vehicle, the seal including a second plastic material different from the first plastic material, the second plastic material including a thermoplastic elastomer having at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less; the mounting bracket is formed from a first injection molding operation and the seal is formed from a second injection molding operation subsequent to the first injection molding operation such that the seal is overmolded onto the mounting bracket. Mounting system. Article XIV. The mounting system of clause XIII, wherein the mounting bracket defines a bracket channel, and the seal is at least partially disposed within the bracket channel. Article XV. The mounting system of clause XIII or XIV, further comprising a cover coupled to the mounting bracket to at least partially conceal the mounting bracket. Article XVI. The mounting system of clause XV, wherein the seal is further defined as a first seal, and the window assembly further includes a second seal interposed between the mounting bracket and the cover to prevent the ingress of debris between the mounting bracket and the cover. Article XVII. The mounting system of any one of clauses XIII-XVI, wherein the first plastic material is a thermoplastic semi-crystalline polymer. Article XVIII. The mounting system of any one of clauses XIII-XVII, wherein the first plastic material is selected from the group consisting of polybutylene terephthalate and polycaprolactam. Article XIX. The mounting system of any one of clauses XIII to XVIII, wherein the second plastic material is a thermoplastic elastomer. Article XX. The mounting system of clause XIX, wherein the thermoplastic elastomer is a thermoplastic urethane. Article XXI. the component is further defined as a sensor, and the component receptacle is further defined as a sensor opening extending through the mounting bracket; the mounting bracket is configured to support the sensor such that the sensor is aligned with the sensor opening. A mounting system according to any one of clauses XIII to XX. Article XXII. a mounting system as described in clause XXI; a transparent pane including an inner surface and an opposing outer surface, the inner surface defining the mounting surface of the vehicle; the seal engages the inner surface of the transparent window pane to prevent the ingress of debris between the mounting portion and the inner surface of the transparent window pane. Window assembly.

Claims

1. 1. A window assembly configured to house a sensor, comprising: a transparent pane including an interior surface and an opposing exterior surface; a mounting bracket including a mounting portion coupled to the inner surface of the transparent window pane, the mounting portion defining an overall mounting area bounded by a perimeter of the mounting portion and defining a sensor opening within the perimeter of the mounting portion, the mounting bracket comprising a first plastic material having at least one of a modulus of elasticity greater than or equal to 1000 MPa and a Shore D hardness greater than or equal to 70, the mounting bracket configured to support the sensor such that the sensor is aligned with the sensor opening; a seal coupled to the mounting bracket along the periphery of the mounting portion and engaging the inner surface of the transparent window pane to prevent the ingress of debris between the mounting portion and the inner surface of the transparent window pane, the seal comprising a second plastic material different from the first plastic material and having at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less. Window assembly.

2. The window assembly of claim 1 , wherein the mounting bracket defines a bracket channel, and the seal is at least partially disposed within the bracket channel.

3. The window assembly of claim 1 , further comprising a cover coupled to the mounting bracket to conceal the sensor.

4. 4. The window assembly of claim 3, wherein the seal is further defined as a first seal, and the window assembly further includes a second seal interposed between the mounting bracket and the cover to prevent the ingress of debris between the mounting bracket and the cover.

5. The window assembly of claim 1 , wherein the mounting bracket defines a notch configured to receive a vehicle rearview mirror.

6. the first plastic material is a thermoplastic semi-crystalline polymer; and / or the first plastic material is selected from the group consisting of polybutylene terephthalate and polycaprolactam; A window assembly according to any one of claims 1 to 5.

7. The window assembly according to any one of claims 1 to 5, wherein the second plastic material is a thermoplastic elastomer.

8. 1. A method of forming a window assembly configured to house one or more sensors, comprising: providing a transparent window pane having an inner surface and an opposing outer surface; forming a mounting bracket having a mounting portion defining a total mounting area bounded by a perimeter of the mounting portion and defining a sensor opening within the perimeter of the mounting portion, the mounting bracket comprising a first plastic material having at least one of a modulus of elasticity greater than or equal to 1000 MPa and a Shore D hardness greater than or equal to 70, the mounting bracket configured to support the sensor such that the sensor is aligned with the sensor opening; coupling a seal to the mounting bracket along the periphery of the mounting portion, the seal comprising a second plastic material different from the first plastic material and having at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less; and coupling the mounting bracket to the inner surface of the transparent window pane such that the seal engages the inner surface of the transparent window pane to prevent the ingress of debris between the mounting portion and the inner surface of the transparent window pane. method.

9. 1. A mounting system configured to support a component relative to a mounting surface of a vehicle, comprising: a mounting bracket including a mounting portion configured to be coupled to the mounting surface of the vehicle, the mounting bracket defining a component receptacle configured to support the component, the mounting bracket including a first plastic material, the first plastic material including a thermoplastic semi-crystalline polymer having at least one of a modulus of elasticity of 1000 MPa or greater and a Shore D hardness of 70 or greater; a seal coupled to the mounting bracket and configured to engage the mounting surface of the vehicle to prevent the ingress of debris between the mounting portion and the mounting surface of the vehicle, the seal including a second plastic material different from the first plastic material, the second plastic material including a thermoplastic elastomer having at least one of a modulus of elasticity of 50 MPa or less and a Shore A hardness of 80 or less; the mounting bracket is formed from a first injection molding operation and the seal is formed from a second injection molding operation subsequent to the first injection molding operation such that the seal is overmolded onto the mounting bracket. Mounting system.

10. The mounting system of claim 9 , wherein the mounting bracket defines a bracket channel, and the seal is at least partially disposed within the bracket channel.

11. The mounting system of claim 9 , further comprising a cover coupled to the mounting bracket for at least partially concealing the mounting bracket.

12. The first plastic material is selected from the group consisting of polybutylene terephthalate and polycaprolactam. A mounting system according to any one of claims 9 to 11.

13. An installation system described in any one of claims 9 to 11, wherein the thermoplastic elastomer is a thermoplastic urethane.

14. the component is further defined as a sensor, and the component receptacle is further defined as a sensor opening extending through the mounting bracket; the mounting bracket is configured to support the sensor such that the sensor is aligned with the sensor opening.

10. The mounting system of claim 9.

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