Glass-Roof Sensor Mounting Assembly With Integrated Cover-Bracket Alignment
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Solution Overview
Problem
Conventional sensor mounting assemblies for vehicles require multiple mounting structures, necessitating multiple datum/pins or roof holes, complicating assembly and increasing costs.
Innovation Solution
A single mounting structure combining a cover and a bracket, which is adjustable and requires only one datum/pin or roof hole, allowing for improved assembly quality and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mounting structures are used, then the sensor can be securely mounted on the vehicle roof, but the assembly complexity increases and more datum/pins or roof holes are required
Solution Approach 1:
The patent combines multiple mounting structures into a single integrated mounting structure that includes a base portion with first and second mounting features, and a cover portion with corresponding features. This merging reduces the number of separate components and datum requirements while maintaining secure mounting capability.
Solution Approach 2:
The single mounting structure serves multiple functions: it provides secure mounting through its base portion, protects the sensor through the cover portion, and enables alignment through integrated datum features. This multi-functionality eliminates the need for separate mounting structures while maintaining reliability.
2Reliability
If multiple mounting structures are used, then the sensor can be securely mounted, but the number of datum/pins or roof holes increases
Solution Approach 1:
The patent merges multiple mounting structures into one integrated structure that requires fewer roof holes. The base portion and cover portion work together as a single unit, reducing the total number of penetration points needed in the roof while maintaining secure sensor mounting.
3Device complexity
If a single mounting structure is used, then the assembly complexity is reduced and fewer roof holes are needed, but the fit and finish adjustability may be compromised
Solution Approach 1:
The mounting structure incorporates adjustable features that allow dynamic adaptation to different sensor positions and orientations. The base portion and cover portion can be positioned and secured with adjustability, enabling fit and finish customization while maintaining the simplicity of a single integrated structure.
Data Source
AI summary
A sensor mounting assembly is provided. The sensor mounting assembly includes a cover having a first end segment and a plurality of attachment features. The first end segment is coupled to a glass roof of a vehicle. The cover is configured to enclose a sensor that is disposed proximally to the glass roof. The sensor mounting assembly further includes a bracket that is coupled to a roof rail located beneath the glass roof of the vehicle. The bracket has a first portion and a second portion. The first portion is configured to secure the sensor proximally to the glass roof of the vehicle and the second portion includes a plurality of mating features to receive the plurality of attachment features that is configured to align the cover with the bracket.