Over-Molded Vehicle Window Glass Bolt Assembly for Large Gaps
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Solution Overview
Problem
The existing methods for manufacturing vehicle-window glass assemblies face challenges in accommodating large gaps between the glass and vehicle-door sheet metal, as standard bolts and injection-molded encapsulations with materials like PVC or TPE struggle to meet torque requirements and maintain positioning accuracy due to material limitations and shrinkage issues.
Innovation Solution
A vehicle-window glass assembly featuring an over-molded bolt with a base, thread rod, and injection-molded part, where the injection-molded part has a higher tensile strength than the encapsulation material, and includes a positioning portion for precise alignment, along with a shim for additional support, allowing the assembly to adapt to varying gaps and maintain mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the length of the bolt is increased to overcome the large gap between glass and vehicle-door sheet metal, then the gap requirement is met, but the assembly space limitation prevents the longer bolt from being used
Solution Approach 1:
The bolt system is segmented into two parts: a standard-length bolt (within assembly space limits) and an injection-molded encapsulation that extends the effective reach. The encapsulation material fills the gap between the bolt head and the vehicle-door sheet metal, allowing the bolt to function as if it were longer without actually increasing the bolt's physical length beyond space constraints.
Solution Approach 2:
The injection-molded encapsulation acts as an intermediary element between the bolt and the vehicle-door sheet metal. It fills the large gap (greater than 10mm) and provides a mechanical connection that allows the standard-length bolt to effectively reach and secure the glass to the door sheet metal without requiring the bolt to physically span the entire gap.
2Manufacturing precision
If the thickness of injection-molding material is increased to lift the bolt relative to the glass surface, then the distance between bolt base and vehicle-door sheet metal is reduced, but shrinkage of the injection-molded encapsulation affects positioning accuracy of the bolt
Solution Approach 1:
The patent changes the material parameters by selecting injection-molding materials with specific properties: tensile strength greater than 15 MPa and shrinkage rate less than 0.8%. This parameter optimization allows the encapsulation to maintain dimensional stability (minimal shrinkage) while providing sufficient mechanical strength to lift the bolt and maintain positioning accuracy during the tightening process.
3Adaptability or versatility
If materials with less tensile strength (such as TPE) are used to form the injection-molded encapsulation, then appearance or function requirements are met, but the torque requirement cannot be met when nuts are screwed
Solution Approach 1:
The patent employs composite material selection where the injection-molded encapsulation is made from materials combining flexibility (for appearance and function) with sufficient strength (tensile strength > 15 MPa). Examples include TPE with enhanced properties, PP, PA, or PC/ABS materials that balance elastomeric flexibility with structural integrity to withstand torque application when nuts are screwed.
Data Source
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AI summary
The present disclosure provides a vehicle-window glass assembly and a method for manufacturing the same. The vehicle-window glass assembly comprises: a vehicle-window glass and its injection-molded encapsulation; and an over-molded bolt comprising a base, a thread rod and an injection-molded part. One end of the thread rod is fixedly connected to the base, and the injection-molded part covers at least a part of the base. The injection-molded encapsulation covers at least a part of the injection-molded part such that the over-molded bolt and the vehicle-window glass are fixed to each other, and material of the injection-molded part has a tensile strength greater than that of material of the injection-molded encapsulation. This vehicle-window glass assembly can be adapted to various vehicle models with a large gap between a surface of a vehicle-window glass and a vehicle-door sheet metal on which the vehicle-window glass requires to be mounted, and can ensure the positioning accuracy of the bolt in case that vehicle manufacturers require to use a specific material with a low tensile strength to form the injection-molded encapsulation of the vehicle-window glass.