Rigid Shipping Insert for Motor Vehicle Windshield Molding
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Solution Overview
Problem
The existing methods for shipping extruded plastic moldings attached to vehicle windshields often result in deformation or distortion due to the concentration of weight on flexible portions during handling and shipping, leading to changes in the molding's orientation and shape.
Innovation Solution
A shipping insert made of elongated, substantially rigid plastic material that extends along the bottom edge of the windshield, distributing weight evenly and incorporating a tongue portion to maintain the molding's shape and prevent deformation, along with an upwardly projecting hook-shaped rib to secure the insert in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the windshield weight is supported by two spaced support rails on the bottom wall of the shipping container, then the shipping container structure is simple, but the concentrated weight on the flexible molding causes deformation and orientation changes
Solution Approach 1:
A rigid shipping insert is introduced as an intermediary component between the support rails and the flexible molding. The insert has a U-shaped cross-section that receives the molding, with a bottom surface that contacts the support rails and sides that contact the molding, thereby distributing the windshield weight along the length of the molding rather than concentrating it at two points, preventing deformation while maintaining structural simplicity
Solution Approach 2:
The shipping insert changes the weight distribution parameter from concentrated point loads at two support rails to distributed line loads along the entire length of the molding. This parameter change transforms the stress pattern on the flexible molding from high-stress concentrated loading to low-stress distributed loading, preventing deformation
2Reliability
If large U-shaped shipping clips are used to receive the lower edge portion of the windshield and bottom molding, then the molding is protected from deformation, but the entire weight of the windshield is transferred through the molding to the two shipping clips causing distortion
Solution Approach 1:
The shipping insert is segmented into a U-shaped cross-section with a bottom surface and two sides, where the bottom surface contacts the support rails and the sides contact the molding. This segmentation allows the insert to distribute weight along its length rather than concentrating it at discrete clip locations, protecting the molding from deformation while avoiding the weight concentration problem of traditional clips
Solution Approach 2:
The rigid shipping insert serves as an intermediary that bears the windshield weight on its bottom surface and transfers it distributed to the support rails, while its sides protectively contact the molding without transferring concentrated loads, thereby simultaneously achieving protection and preventing distortion
3Adaptability or versatility
If the molding is left flexible to allow sealing function, then the molding can seal the windshield properly, but the flexible portion deforms under the combined weight and handling stresses during shipping
Solution Approach 1:
The shipping insert provides localized rigid support to the flexible molding through its U-shaped cross-section that receives and contacts the molding along its entire length. This local rigid support counteracts the flexibility of the molding during shipping, preventing deformation and orientation changes, while allowing the molding to remain flexible for its sealing function during installation
Solution Approach 2:
The rigid shipping insert acts as a structural counterbalance to the flexible molding, providing opposing rigidity that counteracts the deformation forces caused by weight and handling stresses. The insert's rigid structure resists the bending forces that would otherwise cause the flexible molding to change orientation or shape during shipping
Data Source
AI summary
A motor vehicle window panel or windshield has a lower edge portion with an attached extruded plastic molding having a downwardly projecting portion defining a cavity with an inlet gap for receiving a projecting fin on a cowl panel. A shipping insert of extruded substantially rigid plastics material supports the windshield and attached molding during shipping and handling and includes a base portion adapted to seat on shipping container support members and a tongue portion spaced above the base portion and projecting through the inlet gap into the cavity to support the molding. The insert also has an upper portion supporting a solid locating flange of the molding attached to a bottom edge of the windshield. The base portion of the insert has inclined opposite edge surfaces to facilitate sliding on the support members, and also has an upwardly projecting hook rib for retaining the insert on the molding.