Overmolded Window Sensor Mount With Seal for NVH and Debris Control
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Solution Overview
Problem
Conventional vehicle component mounting systems, such as those for sensors, are prone to noise, vibration, and harshness (NVH) due to exposure to outside elements like water and debris, and require improved designs to enhance durability and performance.
Innovation Solution
A mounting system featuring a thermoplastic semi-crystalline polymer bracket with a high elastic modulus and Shore D hardness, combined with a thermoplastic elastomer seal of lower elastic modulus and Shore A hardness, which is overmolded onto the bracket to inhibit debris ingress and reduce NVH.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting systems are used to support components on vehicle mounting surfaces, then the components can be mounted, but the system is prone to noise, vibration, and harshness (NVH) and sensitivity to outside elements
Solution Approach 1:
The mounting bracket is constructed from composite materials including a rigid support structure made of thermoplastic semi-crystalline polymer and a damping layer made of viscoelastic material. This composite structure provides both structural integrity and NVH reduction, resolving the contradiction between mounting reliability and vibration resistance.
Solution Approach 2:
The patent utilizes materials with specific parameter ranges: the thermoplastic semi-crystalline polymer has an elastic modulus of 1000 MPa or greater and Shore D hardness of 70 or greater, while the viscoelastic material has an elastic modulus of 50 MPa or less and Shore A hardness of 80 or less. These parameter specifications ensure optimal balance between structural support and vibration damping.
2Reliability
If conventional mounting systems are used to support components on vehicle mounting surfaces, then the components can be mounted, but the system is sensitive to outside elements such as water, dirt, and other debris
Solution Approach 1:
A flexible seal is integrated into the mounting bracket, made of thermoplastic elastomer material, which forms a protective barrier between the mounting surface and outside elements. This flexible seal prevents ingress of water, dirt, and debris while accommodating thermal expansion and contraction, resolving the contradiction between protection and environmental sensitivity.
Solution Approach 2:
The seal is constructed from thermoplastic elastomer composite material that combines flexibility for sealing with durability for long-term protection. This composite material approach ensures reliable protection from debris while maintaining the sealing function under various environmental conditions.
3Ease of manufacture
If a single material is used for the mounting bracket, then the manufacturing process is simpler, but the system cannot simultaneously provide high structural support and effective vibration damping
Solution Approach 1:
The patent merges the support structure and damping layer into a single integrated mounting bracket component. The rigid thermoplastic semi-crystalline polymer support structure and the viscoelastic damping layer are combined in one piece, providing both structural support and vibration damping functions simultaneously. This integration maintains manufacturing simplicity while achieving superior NVH performance.
Solution Approach 2:
The integrated mounting bracket uses composite materials with distinct functional properties: the thermoplastic semi-crystalline polymer provides structural rigidity (elastic modulus ≥1000 MPa, Shore D hardness ≥70), while the viscoelastic material provides vibration damping (elastic modulus ≤50 MPa, Shore A hardness ≤80). This composite approach enables both structural support and NVH reduction in a single manufactured component.
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 effectively supports vehicle components while preventing debris ingress and reducing noise, vibration, and harshness, thereby enhancing the durability and performance of the mounting system.
Implementation Method 1
The first plastic material comprises a thermoplastic semi-crystalline polymer having at least one of an elastic modulus of 1000 MPa or greater and a Shore D hardness of 70 or greater
Implementation Method 2
The first plastic material comprises a thermoplastic semi-crystalline polymer having at least one of an elastic modulus of 1000 MPa or greater and a Shore D hardness of 70 or greater
Implementation Method 3
The second plastic material comprises a thermoplastic elastomer having at least one of an elastic modulus of 50 MPa or less and a Shore A hardness of 80 or less
Implementation Method 4
The second plastic material comprises a thermoplastic elastomer having at least one of an elastic modulus of 50 MPa or less and a Shore A hardness of 80 or less
Implementation Method 5
The mounting bracket is formed from a first injection molding operation, and the seal is formed from a second injection molding operation, subsequent to first injection molding operation, such that the seal is overmolded to the mounting bracket
Data Source
AI summary
A mounting system configured to support a component relative to a mounting surface of a vehicle includes a mounting bracket including a mounting portion configured to be coupled to the mounting surface of the vehicle. The mounting bracket defining a component receptacle configured to support the component. The mounting bracket comprises a first plastic material. The mounting system also includes a seal coupled to the mounting bracket and configured to engage the mounting surface of the vehicle to inhibit ingress of debris between the mounting portion and the mounting surface of the vehicle. The seal comprises a second plastic material, different than the first plastic material. The mounting system may be included in a window assembly where the mounting surface of the vehicle is an inner surface of a transparent pane and the component is a sensor.