Encapsulated Fixed Window Module With Flush Over-Molding
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Solution Overview
Problem
Conventional motor vehicle window modules suffer from issues such as water leakage, noise, fit and finish problems, and difficult assembly due to their assembly from discrete components, and flush configurations often result in sink marks and surface defects from uneven over-molded material distribution.
Innovation Solution
An encapsulated fixed window module design with consistent thickness of over-molded material to prevent sink marks, featuring protruding lips and constant offset to ensure even cooling and improved aesthetic appearance, using co-extruded profiles and antifriction layers for seamless integration with movable windows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the window pane is placed flush with the division post, then the appearance is enhanced, but a large offset is created requiring excessive over-molded material which causes sink marks and surface defects
Solution Approach 1:
The protruding lip is pre-formed on the division post before the over-molding process. This preliminary structure controls the flow and distribution of over-molded material, ensuring uniform thickness and preventing sink marks while maintaining the flush appearance between window pane and division post.
2Ease of manufacture
If conventional discrete component assembly is used, then manufacturing flexibility is maintained, but water leakage, noise, and fit and finish problems occur
Solution Approach 1:
The division post and surrounding trim are merged into a single integrated component through over-molding. This combines multiple discrete components (division post, trim pieces, sealing elements) into one monolithic structure that eliminates gaps and interfaces where water and noise could penetrate, while maintaining manufacturing efficiency.
3Shape
If the exterior wall is positioned close to the interior surface, then the offset is reduced, but the guiding mean cannot be properly received
Solution Approach 1:
The guiding groove is formed by the lateral wall extending from the exterior wall, creating a three-dimensional receiving structure. This allows the guiding mean to be received in a direction perpendicular to the offset measurement, enabling proper guiding function while maintaining minimal offset between the exterior wall and interior surface.
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
Enhances the aesthetic appearance and reduces the risk of surface defects by maintaining consistent thickness and using protruding lips to evenly distribute material, ensuring flush integration with movable windows and improved assembly quality.
Implementation Method 1
The edges of the pane on which the injection molded trim will adhere are cleaned and primed to promote adhesion and to create a water-impervious seal in the formed article
Implementation Method 2
said at least one protruding lip is elastically deformable from a first unconstrained position to a second constrained position in which said at least one protruding lip is elastically deformed, and wherein said at least one protruding lip is compressed between said exterior wall and said interior surface so as to adopt said second position
Data Source
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AI summary
An encapsulated fixed window module for a motor vehicle, comprising: a fixed window pane, a first division post profile defining a longitudinal groove configured to receive a guiding mean carried by a movable window pane, and having an exterior wall facing a fixed pane interior surface, and an over-molded material securing said first division post profile to said fixed window pane, said over-molded material comprising a first over-molded portion extending between said division post exterior wall and said fixed pane interior surface and a second over-molded portion extending between said lateral wall and said interior surface, wherein said first portion is in contact with at least one protruding lip which is located between said exterior wall and said interior surface, said at least one protruding lip being compressed and elastically deformed between said exterior wall and said interior surface to prevent mold bleeds.