Rear View Housing Bezel Assembly for Wind Noise Reduction
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Solution Overview
Problem
Traditional rear view device housings experience wind noise due to the separation edge location in high-speed airflow zones, and manufacturing one-piece housings with injection molding is complex and costly.
Innovation Solution
The separation edge is relocated to the inside panel of the bezel portion, with a clamp and protrusion design that overlap to create a flush surface, allowing for a simpler two-piece injection molding process and reducing wind noise by positioning the edge in a low-pressure air zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the separation edge is located in the channel (traditional design), then the housing protects against wind noise and collects water droplets, but wind noise increases due to high speed airflow around the separation edge
Solution Approach 1:
The housing is divided into two separate components (scalp portion and bezel portion) that are connected via a clamping mechanism. This segmentation allows the separation edge to be positioned on the inside panel where airflow is slower, reducing wind noise while maintaining manufacturability through modular assembly
Solution Approach 2:
A clamping connection mechanism acts as an intermediary between the scalp portion and bezel portion, enabling them to be securely assembled after separate manufacturing. This mediator allows the separation edge to be optimally positioned without requiring complex one-piece molding
2Device complexity
If a one-piece housing is manufactured using injection molding, then the separation edge is eliminated and manufacturing is simplified, but the process becomes complex and results in thick walled moldings
Solution Approach 1:
The housing is segmented into two separately manufacturable components that can be produced using standard injection molding processes without the complexity and thick wall issues of one-piece molding. The segmentation enables optimized wall thicknesses and simpler mold designs for each component
Solution Approach 2:
The two separately manufactured components are merged through a clamping connection mechanism that creates a unified housing structure. This merging achieves the structural integrity of a one-piece design while retaining the manufacturing advantages of separate component production
3Shape
If the scalp portion and bezel portion are connected at the separation edge in the channel, then the housing provides aerodynamic shaping, but wind noise increases due to high speed airflow at the separation edge
Solution Approach 1:
The separation edge is positioned on the inside panel where the local airflow conditions are different (lower speed) compared to the external channel area. This local repositioning maintains the overall aerodynamic shape while reducing wind noise at the specific separation location
Data Source
AI summary
A housing for a rear view element of a rear view device for a vehicle includes a scalp portion including a first circumferential edge being c-shaped extending at least partially around an opening of the scalp portion, a lower casing portion including a second circumferential edge being c-shaped extending at least partially around an opening of the lower casing portion, and a bezel including a third circumferential edge having a lip portion extending at least partially around the bezel section.