Two-Color Molded Window Glass Holder
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Solution Overview
Problem
Existing methods for producing holder-equipped window glass face challenges such as long curing times for adhesives, potential holder displacement, quality issues due to linear expansion coefficient differences, and risk of window glass breakage from mechanical attachment.
Innovation Solution
A two-color molding process integrating a soft thermoplastic elastomer inner layer and a hard outer layer with fiber reinforcement, eliminating the need for adhesives and mechanical holes, ensuring precise attachment and enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an urethane type adhesive is used to attach the holder to the window glass, then the holder can be attached to the window glass, but it takes time (from 24 to 48 hours) for curing, reducing productivity
Solution Approach 1:
The invention extracts and eliminates the adhesive curing process entirely by using a mechanical attachment method with a holder that has a holding portion clamping the window glass edge and a fitting portion connected to the regulator, replacing the chemical bonding process with direct mechanical connection
Solution Approach 2:
The invention replaces the chemical adhesive bonding system with a mechanical fastening system consisting of a holder with clamping and fitting portions that mechanically connect the window glass to the regulator, eliminating the need for curing time
2Reliability
If an urethane type adhesive is used to attach the holder to the window glass, then the holder can be attached to the window glass, but the holder may undergo displacement in position relative to the window glass during the aging process, affecting quality
Solution Approach 1:
The holder position is precisely determined and fixed during the attachment process itself through mechanical clamping, with no subsequent aging or curing process that could cause displacement, ensuring position precision is maintained throughout the product lifecycle
3Strength
If the holder is made of a hard resin (an engineering plastic), then the holder has sufficient strength, but the difference in the linear expansion coefficient between the window glass and the holder causes the holder to peel from the window glass, reducing quality
Solution Approach 1:
The holder is divided into a holding portion that contacts the window glass and a fitting portion that connects to the regulator, allowing different material properties or designs in each section to optimize both strength and thermal expansion compatibility
Solution Approach 2:
The holder uses a composite structure combining hard resin for strength with design features that accommodate thermal expansion differences, such as flexible mounting mechanisms or expansion joints, preventing peeling while maintaining structural integrity
4Productivity
If a hole is drilled in the window glass to attach the holder mechanically, then the holder can be attached without adhesive curing time, but the window glass may be broken starting from a fine crack at the periphery of the hole, reducing reliability
Solution Approach 1:
The invention extracts and eliminates the hole-drilling process from the window glass by using a holder with a holding portion that clamps the edge of the glass without penetrating it, removing the source of stress concentration and potential crack initiation
Solution Approach 2:
The holder design incorporates a holding portion that distributes attachment forces along the glass edge rather than concentrating them at a single hole location, providing beforehand protection against stress concentration and crack propagation
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
This approach significantly increases productivity and quality by eliminating adhesive curing times, preventing holder displacement, and reducing the risk of window glass breakage, while maintaining precise attachment and absorbing thermal expansion differences.
Implementation Method 1
a soft thermoplastic elastomer inner layer and a hard outer layer with fiber reinforcement, eliminating the need for adhesives and mechanical holes, ensuring precise attachment and enhanced durability
Implementation Method 2
absorbing thermal expansion differences
Implementation Method 3
a two-color molding process integrating a soft thermoplastic elastomer inner layer and a hard outer layer with fiber reinforcement
Data Source
Figure 1
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AI summary
To provide a holder-equipped window glass capable of increasing the quality and productivity and capable of preventing breakage of the window glass to be caused by attachment of the holder, and a process for its production. A holder main body 18 is an integrally molded product comprising an inner layer portion 26 and an outer layer portion 28. The inner layer portion 26 is constructed to be U-shaped in cross section to clamp a part of a lower edge 12B of a window glass 12 in the thickness direction of the lower edge 12B. Further, the outer layer portion 28 is located outside the inner layer portion 26, is made of a material harder than the inner layer portion 26 and is constructed to be U-shaped in cross section. This outer layer portion 28 is provided with a connecting portion 16. This connection portion 16 is projecting in a direction departing form the lower edge 12B of the window glass 12.