Vehicle Backlite Assembly with Integrated Belt Drive
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Solution Overview
Problem
Current power sliding backlite window assemblies in pickup trucks face challenges due to the high cost and weight of aluminum frames, complex assembly processes, and interference issues with adhesive and vehicle frames, as well as the need for additional metal brackets to support motor drive assemblies.
Innovation Solution
A self-contained drive mechanism with a support channel for sliding windows, using a motor attached to a toothed sprocket driving a toothed belt, integrated with structural plastic components for guiding and styling, and tensioned by springs to prevent belt unwrapping, allowing for simpler assembly and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an aluminum frame with overmolded plastic is used for the backlite assembly, then the structural strength and appearance are improved, but the manufacturing cost and complexity increase due to multiple machining operations
Solution Approach 1:
The patent combines the frame structure, styling features, and water management functions into a single molded plastic component. The support structure includes integrated features such as the groove for receiving the drive mechanism, the channel for adhesive application, and styling elements, eliminating the need for separate aluminum frame and overmolding processes.
Solution Approach 2:
The invention changes the material parameter from metal (aluminum) to polymer (molded plastic), which fundamentally alters the manufacturing process from machining to molding. This material substitution enables integration of multiple functions into a single component while maintaining structural requirements.
2Reliability
If the backlite assembly is bonded to the vehicle flange, then the installation reliability is improved, but the assembly process becomes complex due to interference with adhesive and vehicle frame
Solution Approach 1:
The patent segments the backlite assembly into distinct functional components: the support structure with integrated bonding features, the separate drive mechanism, and the glass panels. The support structure includes a dedicated channel for adhesive application and positioning features that ensure proper orientation during installation, allowing the assembly to be bonded without rotation while simplifying the overall assembly process.
Solution Approach 2:
The support structure acts as an intermediary between the backlite assembly and the vehicle flange. It includes an integrated adhesive channel and positioning features that mediate the bonding process, ensuring proper alignment and preventing interference with the adhesive application and vehicle frame.
3Ease of operation
If a cable and drum system is used to power the sliding window, then the motor can be located behind the rear seats, but the drum height and packaging space increase
Solution Approach 1:
The patent extracts the cable and drum system from the backlite assembly, locating the drive mechanism separately within the support structure. This eliminates the need for a compact drum within the backlite, allowing the motor to be positioned flexibly while reducing the packaging space required for the drum mechanism.
Solution Approach 2:
The invention repositions the drive mechanism from a vertical drum configuration to a horizontal belt-driven system integrated into the support structure. This dimensional change eliminates the height requirement of the drum while maintaining the motor positioning flexibility, as the belt drive system can be arranged in the available space within the support structure.
4Stability of the object's composition
If additional metal brackets are used to support the motor drive assembly, then the mounting stability is improved, but the overall weight and cost increase
Solution Approach 1:
The patent merges the mounting support function into the molded plastic support structure itself. The support structure includes integrated features such as recesses, ribs, and bonding surfaces that provide mounting stability without requiring separate metal brackets, thereby reducing weight and eliminating additional fastening hardware.
Solution Approach 2:
The invention uses molded plastic as a composite material that combines structural support, mounting, and styling functions. The plastic support structure can be designed with varying wall thicknesses, reinforcement ribs, and bonding surfaces to achieve the required mounting stability while maintaining lightweight characteristics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, lightweight, and easily assembled backlite assembly that minimizes interference with vehicle frames and adhesive, while maintaining necessary styling and water management functions, enabling simpler installation and reduced packaging space.
Implementation Method 1
the belt is tensioned by springs that apply force between the belt retaining body and a bushing
Data Source
AI summary
In an aspect, the invention is directed to a backlite assembly for a vehicle such as a pickup truck. The backlite assembly incorporates a motor assembly and a motor driven belt engaged with a guide rail that can be mounted to a structural support that is bonded to the fixed windows of the backlite assembly. A motor driven belt is used to actuate a movable window between closed and open positions. The lower support can also integrate the rail directly therein. The lower support can additionally integrate a housing for the motor assembly.