Rear Windshield Protection Box Foam Encapsulation
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Solution Overview
Problem
The increasing complexity of electrical components in rear vehicle windows, particularly in the wet area, leads to susceptibility to moisture-related faults such as short circuits and system failure due to inadequate sealing of cable connections and protective housings, which are difficult to maintain and secure.
Innovation Solution
A rear window with a protective box featuring a body connection made from metals or polymers, a foam-encapsulated protective box with a flange for secure sealing, and a method for producing this setup that includes a foam encapsulation process to fix the protective box base to the body connection, ensuring a watertight and stable installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the protective housing is produced from foam material in the foaming process, then the production process is simplified and integrated, but the wall thickness must be large which reduces sealing surface pressure and makes secure sealing difficult
Solution Approach 1:
The protective housing is divided into two parts: a base body produced from foam material during the foaming process, and a separate cover attached later. This segmentation allows the foam base to provide integrated production benefits while the separate cover enables proper sealing without requiring excessive wall thickness.
Solution Approach 2:
The foam encapsulation is applied in advance during the foaming process to create the base body of the protective housing, preparing the installation space and providing initial structural support before the cover is attached in a subsequent step.
2Stability of the object's composition
If thick-walled sides are used for the protective housing, then structural stability is improved, but bubble formation in the foam material becomes problematic and cable bushing sealing becomes difficult to access
Solution Approach 1:
Dividing the protective housing into a foam base body and a separate cover allows for thinner, more manageable wall thickness that reduces bubble formation issues while maintaining structural stability through the combined structure.
Solution Approach 2:
The cable bushings are positioned in the foam base body at locations that remain accessible even with the segmented design, allowing proper sealing and installation without requiring excessive wall thickness throughout the entire structure.
3Reliability
If additional fastening components are added to fix electronic components, then component fixation stability is improved, but the number of work steps and device complexity increases
Solution Approach 1:
The foam encapsulation serves multiple functions simultaneously: it provides structural support for the protective housing base body, acts as adhesive bonding material, and provides electrical insulation. This merging of functions reduces the need for additional fastening components while maintaining component fixation stability.
Solution Approach 2:
The foam material performs multiple roles including structural support, sealing, insulation, and component mounting base, reducing the need for separate fastening components and simplifying the overall device complexity.
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 provides a stable and watertight seal for control electronics and cable plug connections, reducing the risk of moisture-induced faults and facilitating maintenance by ensuring a secure and accessible installation space.
Implementation Method 1
The foam encapsulation seals the protective box base on the body connection and fixes the protective box base on the body connection
Data Source
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AI summary
Rear windshield with protection box for electronic components, comprising: a. a car body connection (1) fastened to a windshield (2), b. a protection box (4) fastened on the car body connection (1) and comprising a protection box base body (4a) and a protection box cover (4b), c. a foam encapsulation (3) of the car body connection (1), wherein the foam encapsulation (3) seals off and fixes the protection box base body (4a) at the car body connection (1).