Encapsulated Fixed Window Module With Sink-Mark-Resistant Overmolding
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Solution Overview
Problem
Conventional fixed window modules in motor vehicles face issues with water leakage, noise, fit, and finish due to assembly from discrete components, and over-molding processes often result in sink marks and surface defects that affect the esthetic appearance.
Innovation Solution
An encapsulated fixed window module design featuring a U-shaped division post with a constant thickness over-molded material configuration that prevents sink marks by ensuring consistent cooling and minimizing the appearance of defects, while maintaining a flush configuration that enhances esthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If over-molding process is used to secure division post to window pane, then water leakage and noise are prevented, but sink marks and surface defects occur affecting esthetic appearance
Solution Approach 1:
The patent applies different material properties to different regions of the over-molded material. The first portion has constant thickness for structural integrity and sealing, while the second portion has variable thickness optimized for appearance. This local differentiation allows the sealed regions to maintain reliability while the visible regions achieve smooth, defect-free surfaces.
Solution Approach 2:
The patent changes the thickness parameter of the over-molded material along its length. By transitioning from constant thickness to variable thickness, the design optimizes both the sealing function and the aesthetic appearance, reducing sink marks in visible areas while maintaining adequate material volume for waterproofing in critical regions.
2Ease of manufacture
If discrete components are assembled to create fixed window module, then manufacturing flexibility is improved, but water leakage, noise, and fit issues occur
Solution Approach 1:
The patent merges multiple discrete components (division post, window pane, sealing elements) into a single integrated over-molded structure. This combination eliminates gaps and interfaces between separate parts, thereby preventing water leakage and noise while maintaining manufacturing flexibility through the molding process.
Solution Approach 2:
The patent uses composite construction combining the rigid division post structure with the over-molded material that provides sealing and noise reduction properties. This composite approach maintains the structural benefits of discrete components while adding the sealing advantages of an integrated design.
3Quantity of substance
If offset configuration is used between interior surface and interior wall, then limited over-molded material is required, but appearance issues due to sink marks occur
Solution Approach 1:
The patent applies different thickness characteristics to different portions of the over-molded material. The first portion maintains constant thickness for structural functions, while the second portion uses variable thickness optimized for appearance quality, thereby achieving both material efficiency and aesthetic requirements.
Solution Approach 2:
The patent applies over-molding selectively to different regions with different thickness requirements. Rather than uniform over-molding throughout, the design applies adequate material only where needed for sealing while using reduced material in appearance-critical areas, thus avoiding sink marks while maintaining functionality.
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 effectively addresses the issues of water leakage, noise, and esthetic concerns by providing a secure, noise-reduced, and visually appealing window module with reduced risk of sink marks and surface defects, enhancing the overall appearance and functionality of the vehicle's window modules.
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
a portion of the trim or post surrounding the window pane is fabricated by encapsulating the window periphery with a polymer using injection molding techniques
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, said first over-molded portion having a first thickness which is constant along a major portion of said first over-molded portion, wherein said second over-molded portion has a second thickness which is constant along a major portion of said second portion due to a co-extruded feature or "tooth" on the first division post profile.