Windshield Sensor Mounting Bracket With Integrated Debris Seal

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Solution Overview

Problem

Conventional vehicle components mounted on surfaces like windshields are susceptible to outside elements, leading to issues such as noise, vibration, and harshness (NVH), and there is a need for improved mounting systems that inhibit debris ingress.

Innovation Solution

A window assembly with a mounting bracket made of a high-strength plastic material and a seal made of a flexible plastic material, designed to securely house sensors and prevent debris ingress while reducing NVH, using a two-shot injection molding process to integrate the seal with the bracket.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mounting bracket is used to secure sensors to the windshield, then the sensor mounting stability is improved, but debris can still ingress between the mounting bracket and the windshield surface

Engineering Contradiction:

Improvesensor mounting stabilityVSAvoiddebris ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A seal made of flexible plastic material is integrated into the mounting bracket to form a flexible barrier that prevents debris ingress while accommodating surface irregularities and thermal expansion between the rigid bracket and windshield

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If a rigid mounting bracket is used to support sensors, then the mounting structure strength is improved, but noise and vibration are transmitted to the sensor

Engineering Contradiction:

Improvemounting structure strengthVSAvoidnoise and vibration

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The mounting bracket is formed as a composite structure combining rigid plastic material for structural strength and support, with an integrated flexible seal material that provides vibration isolation and noise reduction while maintaining the overall structural integrity

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If a single-material mounting bracket is used, then the manufacturing process is simplified, but it cannot simultaneously provide both structural strength and vibration isolation

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidvibration isolation performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The seal is integrated directly into the mounting bracket as a unified component, combining the rigid bracket structure and flexible sealing function into a single part that is manufactured in one process, eliminating the need for separate assembly steps while providing both structural support and vibration isolation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

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 secures sensors, reduces noise and vibration, and prevents debris ingress, enhancing the durability and performance of vehicle components.

Implementation Method 1

a mounting bracket (214) including a mounting portion coupled to the inner surface of the transparent pane via an adhesive

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

a seal coupled to the mounting bracket along the perimeter of the mounting portion and engaging the inner surface of the transparent pane to inhibit ingress of debris

Methodology Applied

Scientific EffectPhysical barrier: Physical Containment

Data Source

PatentEP4410602B1A mounting system, a window assembly including the same, and a method of forming the window assembly

Publication Date: 2025.07.23 AGC AUTOMOTIVE AMERICAS CO

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Figure 2A~2B
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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.