Door Mirror Harness Sealing for Wind Noise and Air Leak Reduction
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Solution Overview
Problem
Existing sealing systems for vehicle side-view mirrors fail to effectively reduce wind noise and air leakage at the interface between the mirror and the vehicle body, leading to acoustic interference and potential damage from intrusive elements.
Innovation Solution
A method and system that involves modifying the wire harness assembly by removing a portion of the rigid encasing to expose pins, and then coupling the wire harnesses using a fabric-based tape to form a sealed assembly, thereby preventing air leaks and reducing wind noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If wire harnesses are connected using rigid encasing, then structural stability is improved, but wind noise and air leakage increase due to gaps at the interface
Solution Approach 1:
The patent replaces rigid encasing with flexible tape wrapping around the wire harnesses. The flexible tape conforms to the contours of the wire harnesses and fills gaps at the interface, preventing air leakage and reducing wind noise while maintaining structural stability through the flexible connection.
2Strength
If rigid encasing is used to protect wire harnesses, then mechanical protection is improved, but sealing performance deteriorates due to gaps between components
Solution Approach 1:
The flexible tape acts as a sealing film that wraps around the wire harnesses, filling gaps and crevices that rigid encasing cannot seal. This provides both mechanical protection and effective sealing against air and water intrusion.
Solution Approach 2:
The solution combines the rigid encasing structure with flexible tape material to create a composite sealing system. The rigid portion provides structural support while the flexible tape provides sealing, creating a multi-material system that addresses both mechanical protection and sealing requirements.
3Length of moving object
If gaps are maintained at the mirror interface, then clearance for moving parts is improved, but acoustic interference and fluid intrusion increase
Solution Approach 1:
The flexible tape is applied to seal the gaps at the mirror interface while allowing the necessary clearance for moving parts to be maintained. The tape conforms to the geometry of the interface, filling the gaps that cause acoustic interference and fluid intrusion without restricting the movement clearance.
Data Source
AI summary
A sealing system and method for a mirror assembly of a vehicle is provided. The mirror assembly includes a wire harness assembly in which at least a first wire harness and a second wire harness are coupled together. The first wire harness is protected within a rigid encasing but for an exposed portion. The exposed portion permits freer movement of the internal pins in that area, which promotes a better fit with the adjacent second wire harness. In one example, a foam sheath can used to cover a portion of the wire harness assembly, which is then routed through a gasket. This arrangement is configured to prevent air leaks that might otherwise occur due to gapping between the first wire harness and the second wire harness.