Sunroof Seal Bracket Layout for Thick Roof Flanges
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Solution Overview
Problem
Existing sunroof units face challenges with increased overall thickness due to large flange portions from the roof opening, and complex seal structures that require extensive installation and adjustment.
Innovation Solution
A sunroof unit design featuring a frame with a U-shaped support bracket that receives the flange portion, allowing for height adjustment of seal members and a simple seal configuration, along with a drainage groove to prevent water accumulation, thereby minimizing overall thickness and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the support bracket is designed to accommodate large flange portions, then the sealing capability is improved, but the overall thickness of the sunroof unit increases
Solution Approach 1:
The support bracket incorporates an adjustable mechanism that allows dynamic adaptation to different flange heights. The bracket can be positioned at various heights along the guide wall to match the actual flange portion height, providing sealing capability for large flange portions while maintaining minimal overall thickness when flange portions are small.
Solution Approach 2:
The support bracket's position height is made variable rather than fixed. By changing the vertical position parameter of the support bracket along the guide wall, the system can accommodate different flange heights without requiring a fixed design that would increase overall thickness for all cases.
2Reliability
If seal members are provided along the entire circumference of panels, then sealing performance is improved, but the device complexity increases
Solution Approach 1:
The sealing function is segmented between the rear seal portion (first seal member) and the side seal portion (second seal member). The first seal member seals the rear edge of the opening, while the second seal member seals the side edge, dividing the sealing task into separate components rather than requiring a continuous circumferential seal.
Solution Approach 2:
Instead of providing a continuous circumferential seal around the entire panel perimeter, the invention inverts the approach by providing discrete seal members at specific locations (rear and side edges) where sealing is most critical, reducing complexity while maintaining effective sealing.
3Adaptability or versatility
If the support bracket is fixed at a high position to accommodate large flange portions, then the adaptability to roof variations is improved, but the overall thickness increases
Solution Approach 1:
The support bracket is designed with dynamic positioning capability along the guide wall, allowing it to be adjusted to different heights based on the actual flange portion height. This dynamic adjustment provides adaptability to roof variations without requiring a fixed high position that would increase overall thickness.
Solution Approach 2:
The guide wall serves multiple functions: it provides structural support, guides the support bracket during assembly, and serves as the adjustment track for positioning the support bracket at the appropriate height. This multi-functionality enables adaptability without adding separate adjustment mechanisms that would increase thickness.
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 design effectively suppresses the increase in overall thickness even with large flange portions and provides a straightforward seal configuration for easier installation and adjustment, ensuring effective sealing and water drainage.
Implementation Method 1
a first seal member (31) mounted to the rear molded part (17) in a rear portion of the opening (3) and resiliently contacting an edge of the opening (3)
Implementation Method 2
a second seal member (32) extending in a fore and aft direction and supported by the frame (20) via a support bracket (33) to form a passage (64) for the stay (63) between the second seal member (32) and the rear molded part (17)
Data Source
Figure 1
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AI summary
Increase of an overall thickness of a sunroof unit is suppressed even when a flange portion depending from a side edge of an opening of a roof has a large height. A rear panel 12 contacts an edge of an opening 3 via a rear seal portion 18. The rear seal portion 18 includes a first seal member 31 mounted to a rear molded part 17 in a rear portion of the opening 3 and a second seal member 32 extending in a fore and aft direction and supported by a frame 20 via a support bracket 33 to form a passage for a stay 63 between the second seal member and the rear molded part 17 in a side portion of the opening 3. The frame 20 includes a pair of guide walls 41 disposed more inboard than a side edge of the opening 3 and slidably guiding the slider 40 in the fore and aft direction and a vertical wall 43 formed to stand upright at a position more outboard than the side edge of the opening 3. The support bracket 33 has a U-shaped cross section opened upward and is disposed to receive a flange portion 4 depending from the side edge of the opening 3.