Encapsulated Fixed Window Module With Sink-Mark-Free Division Post
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Solution Overview
Problem
Conventional fixed window modules in motor vehicles face issues such as water leakage, noise, and appearance defects due to their assembly from discrete components, particularly with over-molding processes that can result in sink marks and surface defects.
Innovation Solution
An encapsulated fixed window module design featuring a U-shaped division post with an over-molded material that includes elastically deformable protruding lips to maintain consistent thickness, preventing sink marks and enhancing aesthetic appearance by ensuring the exterior and interior surfaces are flush and visually appealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If over-molding process is used to secure division post to window pane, then water tightness and noise reduction are improved, but appearance quality deteriorates due to sink marks and surface defects
Solution Approach 1:
The patent applies local quality by creating a dual-zone over-molding structure: a first portion with constant thickness for appearance-critical areas (exterior and interior surfaces) and a second portion with variable thickness for structural support. This allows the appearance-critical regions to maintain uniform quality while the structural region provides adequate material for bonding and sealing.
Solution Approach 2:
The over-molded material is segmented into distinct functional portions: a first portion extending from the exterior surface to the interior surface with constant thickness for appearance, and a second portion extending from the interior surface to the division post with variable thickness for structural function. This segmentation resolves the contradiction by assigning different thickness characteristics to different functional zones.
2Manufacturing precision
If offset between interior surface and interior wall is reduced, then appearance quality is improved, but amount of over-molded material is reduced compromising seal integrity
Solution Approach 1:
The patent implements local quality by maintaining a constant thickness in the first portion of the over-molded material that spans the offset region, ensuring appearance quality is not compromised. Meanwhile, the second portion provides additional variable thickness material to ensure adequate seal integrity and structural support where needed.
3Reliability
If amount of over-molded material is increased to improve seal integrity, then water tightness is improved, but appearance quality deteriorates due to sink marks
Solution Approach 1:
The over-molded material is divided into two functional segments: the first portion with constant thickness provides adequate material for appearance-critical exterior and interior surfaces, preventing sink marks. The second portion with variable thickness provides additional material for structural support and sealing functions, ensuring water tightness without compromising appearance.
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 appearance defects by maintaining consistent over-molded material thickness, reducing the risk of sink marks, and enhancing the esthetic appearance of the window module while ensuring a secure and watertight seal.
Implementation Method 1
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
Implementation Method 2
A few of the problems of conventional designs are overcome through the use of over-molding processes by which 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
AI summary
An encapsulated fixed window module for a motor vehicle includes a fixed window pane, a first division post profile defining a longitudinal groove configured to receive a guide carried by a movable window pane. An exterior wall faces a fixed pane interior surface, and an over-molded material secures the first division post profile to the fixed window pane. The over-molded material has a first over-molded portion extending between the division post exterior wall and the fixed pane interior surface and a second over-molded portion extends between the lateral wall and the interior surface. The first portion is in contact with at least one protruding lip which is located between the exterior wall and the interior surface, the at least one protruding lip being compressed and elastically deformed between the exterior wall and the interior surface to prevent mold bleeds.