Patent Description:
This invention relates generally to a mounting system, a window assembly including the same, and a method of forming a window assembly for a vehicle.

Conventional components for vehicles (such as sensors) are mounted to various mounting surfaces of the vehicle, such as the windshield, the pillars, and the like. Such components can be sensitive to outside elements, such as water, dirt, and other debris. Furthermore, the mounting of these components relative to the mounting surface of the windshield can lead to undesirable noise, vibration, and harshness (NVH). To this end, there remains a need for improved mounting systems for housing components such as a sensor relative to a mounting surface of a vehicle. <CIT> describes a windshield assembly for mounting a rain sensor comprising a transparent panel and a mounting bracket of a plastic material for supporting a sensor. The mounting bracket is coupled to the panel via an adhesive.

One general aspect of the present disclosure includes a window assembly configured to house a sensor. The window assembly includes a transparent pane including an inner surface and an opposing outer surface. The window assembly also includes a mounting bracket including a mounting portion coupled to the inner surface of the transparent pane via an adhesive. The mounting portion defines a total mounting area bounded by a perimeter of the mounting portion. The mounting bracket also defines a sensor aperture within the perimeter of the mounting portion. The mounting bracket comprises a first plastic material having at least one of an elastic modulus of <NUM> MPa or greater and a Shore D hardness of <NUM> or greater. The mounting bracket is configured to support the sensor such that the sensor is aligned with the sensor aperture. The window assembly also includes 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 between the mounting portion and the inner surface of the transparent pane. The seal comprises a second plastic material, different than the first plastic material. The second plastic material has at least one of an elastic modulus of <NUM> MPa or less and a Shore A hardness of <NUM> or less.

A further general aspect of the present disclosure includes a method of forming a window assembly configured to house one or more sensors. The method includes providing a transparent pane having an inner surface and an opposing outer surface. The method also includes forming a mounting bracket having a mounting portion defining a total mounting area bounded by a perimeter of the mounting portion, and defining a sensor aperture within the perimeter of the mounting portion. The mounting bracket comprises a first plastic material having at least one of an elastic modulus of <NUM> MPa or greater and a Shore D hardness of <NUM> or greater. The mounting bracket is configured to support the sensor such that the sensor is aligned with the sensor aperture. The method also includes coupling a seal to the mounting bracket along the perimeter of the mounting portion. The seal comprises a second plastic material, different than the first plastic material. The second plastic material has at least one of an elastic modulus of <NUM> MPa or less and a Shore A hardness of <NUM> or less. The method also includes coupling the mounting bracket to the inner surface of the transparent pane via an adhesive such that the seal engages the inner surface of the transparent pane to inhibit ingress of debris between the mounting portion and the inner surface of the transparent pane.

Other advantages of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

With reference to the Figures, wherein like numerals indicate like parts throughout the several views, various configurations of mounting systems <NUM>, <NUM>, <NUM> according to the present disclosure are generally shown. The mounting systems <NUM>, <NUM>, <NUM> according to the present disclosure are configured to support a component <NUM> relative to a mounting surface <NUM> of a vehicle <NUM>. The component <NUM> may be a sensor (such as a camera), a display panel, other vehicle components (such as interior panels, roof panels, body panels, etc.), and like, or combinations thereof. As described in further detail below, the mounting system <NUM> may be configured to support more than one component <NUM> relative to the mounting surface <NUM>.

Referring to <FIG>, a mounting system <NUM> according to the present disclosure includes a mounting bracket <NUM>. The mounting bracket <NUM> is comprised of a first plastic material. In these embodiments, the first plastic material comprises a thermoplastic semi-crystalline polymer. Furthermore, the first plastic material according to these embodiments has at least one of an elastic modulus of <NUM> MPa or greater and a Shore D hardness of <NUM> or greater. In other words, the first plastic material can have only an elastic modulus of <NUM> MPa or greater, only a Shore D hardness of <NUM> or greater, or both an elastic modulus of <NUM> MPa or greater and a Shore D hardness of <NUM> or greater.

In some examples, the first plastic material has an elastic modulus of between <NUM> MPa and <NUM>,<NUM> MPa. For example, the elastic modulus of the first plastic material may be between <NUM> MPa and <NUM> MPa, between <NUM> MPa and <NUM> MPa, between <NUM> MPa and <NUM> MPa, between <NUM> MPa and <NUM> MPa, between <NUM> MPa and <NUM> MPa, between <NUM> MPa and <NUM> MPa, between <NUM> MPa and <NUM> MPa, between <NUM> MPa and <NUM> MPa, and between <NUM> MPa and <NUM>,<NUM> MPa. In examples where the first plastic material is reinforced with additional materials (discussed below), the resulting elastic modulus may be significantly higher (e.g. as high as <NUM>,<NUM> MPa). One suitable technique for measuring modulus is provided in <NPL>" and is incorporated by reference in its entirety. Another suitable technique for measuring modulus is provided in <NPL>".

In some examples, the first plastic material has a Shore D hardness of between <NUM> and <NUM>. For example, the Shore D hardness of the first plastic material may be between <NUM> and <NUM>, between <NUM> and <NUM>, between <NUM> and <NUM>, between <NUM> and <NUM>, between <NUM> and <NUM>, and between <NUM> and <NUM>. One suitable technique for measuring Shore A/D hardness is provided in <NPL>".

In some examples, the first plastic material is selected from the group consisting of polybutylene terephthalate and polycaprolactam (i.e., PA6 nylon), but other materials are contemplated. Also, it should be appreciated that in some examples the first plastic material may be reinforced with additional materials such as carbon fiber or fiberglass.

The size and shape of the mounting bracket <NUM> is not particularly limited for the purposes of this disclosure. Accordingly, the mounting bracket is illustrated schematically in <FIG>. The mounting bracket <NUM> has a mounting portion <NUM> that is configured to be coupled to the mounting surface <NUM> of the vehicle <NUM> (e.g. via an adhesive). It should be appreciated that the mounting portion <NUM> may be coupled to the mounting surface <NUM> of the vehicle <NUM> either directly or indirectly (e.g. with an intermediate component between the mounting portion <NUM> and the mounting surface <NUM>). The mounting portion <NUM> may define a total mounting area <NUM> bounded by a perimeter <NUM> of the mounting portion <NUM>.

Still referring to <FIG>, the mounting portion <NUM> defines one or more component receptacles <NUM> which may be arranged within the perimeter <NUM> of the mounting portion <NUM>. The mounting bracket <NUM> is configured to support the component(s) <NUM> such that the component(s) <NUM> are configured to be at least partially disposed in a respective component receptacle <NUM>. The component(s) <NUM> are typically removably coupled to the mounting bracket <NUM>. For example, the component(s) <NUM> may be fastened to the mounting bracket <NUM> (e.g. via screws, clips, or the like), or the component(s) <NUM> may be disposed in the component receptacle <NUM> via interference fit. Other configurations of coupling the component(s) <NUM> to the mounting bracket <NUM> are contemplated.

In one example, such as shown in <FIG>, the mounting surface <NUM> is a transparent pane <NUM> of a vehicle <NUM>. Here, the mounting system <NUM> is configured to support the component <NUM> relative to the transparent pane <NUM> of the vehicle <NUM>. Particularly, the mounting bracket <NUM> is configured to be coupled to the mounting surface <NUM> defined by the transparent pane <NUM> to support the component <NUM>. In the illustrated example, the component <NUM> is a sensor <NUM> (described below). Here, the mounting bracket <NUM> supports the sensor <NUM> such that the field of view FOV of the sensor <NUM> faces the transparent pane <NUM> (and, thus, the sensor <NUM> looks through the transparent pane <NUM>). In this example, the component receptacle <NUM> is further defined as a sensor aperture <NUM> which extends through the mounting bracket <NUM> and defines define a sensor area <NUM> bounded by a sensor aperture perimeter <NUM>, with the sensor area <NUM> being less than the total mounting area <NUM> of the mounting portion <NUM>. In some examples, the sensor aperture(s) <NUM> are spaced from the perimeter <NUM> of the mounting portion <NUM> (i.e., a portion of the total mounting area <NUM> is disposed between the sensor aperture <NUM> and the perimeter <NUM> of the mounting portion <NUM>). In the example of <FIG>, the mounting surface <NUM> may be a sheet metal surface of the vehicle <NUM>. Here, the mounting bracket <NUM> is configured to be coupled to the mounting surface <NUM> defined by the transparent pane <NUM> to support the component <NUM> relative to the mounting surface <NUM>.

In configurations where the mounting system <NUM> is configured to support more than one component <NUM>, the mounting bracket <NUM> defines a plurality of component receptacles <NUM> configured to support respective components <NUM>. It is to be appreciated that the mounting system <NUM> may be configured to support any number of components <NUM>, such as two, three, four, five, six, or more components <NUM>. In some examples, a single component receptacle <NUM> may be configured to support a plurality of components <NUM>.

As best shown in <FIG>, the mounting system <NUM> also includes a seal <NUM>. The seal <NUM> is comprised of a second plastic material, different than the first plastic material of the mounting bracket <NUM>. In these embodiments, the second plastic material comprises a thermoplastic elastomer. In some examples, the thermoplastic elastomer is further defined as thermoplastic urethane, but other materials are contemplated. Furthermore, the second plastic material according to these embodiments has at least one of an elastic modulus of <NUM> MPa or less and a Shore A hardness of <NUM> or less. In other words, the second plastic material can have only an elastic modulus of <NUM> MPa or less, only a Shore A hardness of <NUM> or less, or both an elastic modulus of <NUM> MPa or less and Shore A hardness of <NUM> or less. In some examples, the second plastic material has an elastic modulus of between greater than <NUM> MPa and <NUM> MPa or less. For example, the elastic modulus of the second plastic material may be between greater than <NUM> MPa and <NUM> MPa, between greater than <NUM> MPa and <NUM> MPa, between greater than <NUM> MPa and <NUM> MPa, between greater than <NUM> MPa and <NUM> MPa, between greater than <NUM> MPa and <NUM> MPa, and between greater than <NUM> MPa and <NUM> MPa. In some examples, the second plastic material has a Shore A hardness of between <NUM> and <NUM>. For example, the Shore A hardness of the second plastic material may be between <NUM> and <NUM>, between <NUM> and <NUM>, between <NUM> and <NUM>, between <NUM> and <NUM>, between <NUM> and <NUM>, between <NUM> and <NUM>, between <NUM> and <NUM>, and between <NUM> and <NUM>.

As best shown in <FIG>, the seal <NUM> is coupled to the mounting bracket <NUM>. Here, the seal <NUM> extends away from the mounting portion <NUM> such that the seal <NUM> is configured to engage the mounting surface <NUM> to inhibit ingress of debris, dust, moisture, and the like in the space between the mounting surface <NUM> and the mounting bracket <NUM> (e.g. the total mounting area <NUM> of the mounting portion <NUM>). The seal <NUM> extends along the perimeter <NUM> of the mounting portion <NUM> of the mounting bracket <NUM> (best shown in <FIG>). It should be appreciated that in some embodiments, such as shown in <FIG>, the seal <NUM> extends along the entire perimeter <NUM> of the mounting portion <NUM> of the mounting bracket <NUM>. However, in other embodiments, the seal <NUM> may extend partially along the perimeter <NUM> (e.g. one side) of the mounting portion <NUM> of the mounting bracket <NUM>. In addition to inhibiting ingress of debris, dust, moisture, and the like in the space between the mounting surface <NUM> and the mounting bracket <NUM>, having the seal <NUM> configured to engage the mounting surface <NUM> also reduces vibrations between the mounting bracket <NUM> and the mounting surface <NUM> and also reduces noise, vibration, and harshness (NVH) that may arise between the mounting bracket <NUM> to the mounting surface <NUM> of the vehicle <NUM>.

A variety of approaches for coupling the seal <NUM> to the mounting bracket <NUM> are contemplated. For example, the seal <NUM> may be overmolded over the mounting bracket <NUM>. The mounting bracket <NUM> and the seal <NUM> may be formed through two shot injection molding. Specifically, the mounting bracket <NUM> may be injection molded with the first plastic material and then the seal <NUM> including the second plastic material may be injection molded over the mounting bracket <NUM>. In other words, the mounting bracket <NUM> may be formed from a first injection molding operation, and the seal <NUM> may be formed from a second injection molding operation, subsequent to the first injection molding operation, such that the seal <NUM> is overmolded to the mounting bracket <NUM>. In these examples, it is important to select the first plastic material and the second plastic material to be compatible for an overmolding process. In some examples, such as shown in <FIG>, the mounting bracket <NUM> defines a bracket channel <NUM>. In some examples, the seal <NUM> is at least partially disposed in the bracket channel <NUM>. For example, the seal <NUM> may be overmolded into the bracket channel <NUM> or press-fit into the bracket channel <NUM> to couple the seal <NUM> to the mounting bracket <NUM>. Other configurations of coupling the seal <NUM> to the mounting bracket <NUM> are contemplated.

Referring to <FIG>, the mounting system <NUM> may further include a cover <NUM> coupled to the mounting bracket <NUM>. Although not required, the cover <NUM> may conceal the component <NUM>. The cover <NUM> may be fastened to the mounting bracket <NUM> (e.g. via screws, clips, or the like), or the cover <NUM> may be coupled to the mounting bracket <NUM> via interference fit. Other configurations of coupling the cover <NUM> to the mounting bracket <NUM> are contemplated. When present, the cover <NUM>, when coupled to the mounting bracket <NUM>, extends away from the mounting surface <NUM>. For example, referring to <FIG>, in configurations where the mounting bracket <NUM> is coupled to a transparent pane <NUM>, the mounting bracket <NUM> is disposed between the transparent pane <NUM> and the cover <NUM>. In another example, referring to <FIG>, the mounting bracket <NUM> may be disposed between the cover <NUM> and the mounting surface <NUM> of the vehicle <NUM>, such as sheet metal. The cover <NUM> is typically referred to as a beauty cover or an applique.

Referring to <FIG>, a mounting system <NUM> according to the present disclosure is configured to house a sensor <NUM> relative to a mounting surface <NUM> (e.g. an inner surface <NUM> of a transparent pane <NUM> of a vehicle <NUM>). In these examples, the mounting system <NUM> may also be referred to as "sensor mounting system <NUM>". The sensor <NUM> may be a camera, rain sensor, light sensor, light detection and ranging (LIDAR) sensor, collision sensor, forward collision sensor, and like, or combinations thereof. As described in further detail below, the sensor mounting system <NUM> may have more than one sensor <NUM>.

In examples where the mounting surface <NUM> of the vehicle <NUM> is an inner surface <NUM> of a transparent pane <NUM> of the vehicle <NUM>, the sensor mounting system <NUM> and the transparent pane <NUM> collectively define the window assembly <NUM>. In some examples, the transparent pane <NUM> is implemented as at least one pane of glass. Where the transparent pane <NUM> is implemented as glass, the transparent pane <NUM> is comprised of any suitable glass composition including, but not limited to, soda-lime glass, aluminosilicate glass, borosilicate glass, boro-aluminosilicate glass, and the like. Those skilled in the art realize that the transparent pane <NUM> may be formed from polymeric materials such as polymethyl methacrylate, polycarbonate, polyvinyl butyral, or the like.

The transparent pane <NUM> has a thickness T1. The thickness T1 of the transparent pane <NUM> may be from about <NUM> to about <NUM>. More specifically, the thickness T1 may be about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>.

As used herein, the term "transparent", refers to a material that allows <NUM>% or more of light transmission in a predefined visible light range to travel therethrough. Typically, the predefined visible light range is the segment of the electromagnetic spectrum that the human eye can view (i.e., visible light). Thus, the predefined visible light range typically refers to wavelengths of light from about <NUM> to about <NUM> nanometers. Where the sensor <NUM> is a LIDAR sensor, however, the transparent pane <NUM> may additionally or alternatively allow <NUM>% or more of light transmission in a predefined visible light range corresponding to operative spectrum of the LIDAR sensor to travel therethrough. For example, the predefined visible light range corresponding to operative spectrum of the LIDAR sensor may be between <NUM> nanometers and <NUM> nanometers. Other spectrums are contemplated.

In some examples, such as best shown in <FIG>, the transparent pane <NUM> is formed as a laminated glazing, such as a windshield. In these examples, the laminated transparent pane <NUM> includes an inner glass substrate 206A defining the inner surface <NUM>, an outer glass substrate 206B defining an outer surface <NUM>, and a polymeric interlayer 206C disposed between the inner glass substrate 206A and the outer glass substrate 206B. The inner glass substrate 206A and the outer glass substrate 206B may be comprised of any suitable glass composition including, but not limited to, soda-lime glass, aluminosilicate glass, borosilicate glass, boro-aluminosilicate glass, and the like. It should be appreciated that the inner glass substrate 206A and the outer glass substrate 206B may be comprised of the same or different glass compositions.

The inner glass substrate 206A may have a thickness TA, and the outer glass substrate 206B may have a thickness TB. The thicknesses TA, TB of the inner glass substrate 206A and the outer glass substrate 206B, respectively, may be any suitable thickness for the application. For example, the thicknesses TA, TB of the inner glass substrate 206A and the outer glass substrate 206B, respectively, may be from about <NUM> to about <NUM>. More specifically, the thicknesses TA, TB, may each be about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. It should be appreciated that the thickness TA and the thickness TB can be the same or different. In one example, the inner glass substrate 206A and the outer glass substrate 206B have the same thickness (i.e., where TA is equal to TB) such that the transparent pane <NUM> is considered a "symmetric" laminate. However, in another example, the inner glass substrate 206A and the outer glass substrate 206B have different thicknesses (i.e., where TA is not equal to TB) such that the transparent pane <NUM> is considered an "asymmetric" laminate. All combinations of the example TA and TB values listed above and all fractional values therebetween are contemplated.

The polymeric interlayer 206C bonds the inner glass substrate 206A and the outer glass substrate 206B such that the polymeric interlayer 206C retains the inner glass substrate 206A and/or the outer glass substrate 206B in the event of impact or breakage of the transparent pane <NUM>. The polymeric interlayer 206C includes a polymer or thermoplastic resin, such as polyvinyl butyral (PVB), ethylene-vinyl acetate (EVA), thermoplastic polyurethane (TPU), and the like. Other suitable materials for implementing the polymeric interlayer 206C may be utilized that provide the requisite performance characteristics regarding optical haze, adhesion to glass, and structural rigidity. Similar to the inner glass substrate 206A and the outer glass substrate 206B, the polymeric interlayer 206C is also substantially transparent or otherwise transparent to light.

Referring to <FIG>, the sensor mounting system <NUM> includes a mounting bracket <NUM>. The mounting bracket <NUM> is comprised of a first plastic material. In these embodiments, the first plastic material may have an elastic modulus of <NUM> MPa or greater. The first plastic material may additionally or alternatively have a Shore D hardness of <NUM> or greater. In some examples, the first plastic material is a thermoplastic semi-crystalline polymer, which may be selected from the group consisting of polybutylene terephthalate and polycaprolactam (i.e., PA6 nylon), but other materials are contemplated. The mounting bracket <NUM> has a mounting portion <NUM> that is configured to be coupled to the mounting surface <NUM> of the vehicle <NUM> (e.g. to the inner surface <NUM> of the transparent pane <NUM>). It should be appreciated that the mounting portion <NUM> may be coupled to the mounting surface <NUM> of the vehicle <NUM> either directly or indirectly (e.g. with an intermediate component between the mounting portion <NUM> and the mounting surface <NUM>). For example, the mounting portion <NUM> may be coupled to the mounting surface <NUM> directly with an adhesive, or, in other examples, an intermediate component may be coupled to the mounting surface <NUM> and the mounting portion <NUM> may be coupled to the intermediate component. The mounting portion <NUM> defines a total mounting area <NUM> bounded by a perimeter <NUM> of the mounting portion <NUM>.

Still referring to <FIG>, the mounting portion <NUM> defines one or more sensor apertures <NUM> within the perimeter <NUM> of the mounting portion <NUM>. The mounting bracket <NUM> is configured to support the sensor(s) <NUM> such that the sensor(s) <NUM> is (are) aligned with a respective sensor aperture <NUM>. For example, as best shown in <FIG>, in configurations where the sensor mounting system <NUM> is included in a window assembly <NUM>, the mounting bracket supports the sensor <NUM> such that the field of view FOV of the sensor <NUM> faces the transparent pane <NUM> (and, thus, the sensor <NUM> looks through the transparent pane <NUM>). The sensor(s) <NUM> is (are) typically removably coupled to the mounting bracket <NUM>. For example, the sensor(s) <NUM> may be fastened to the mounting bracket <NUM> (e.g. via screws, clips, or the like), or the sensor(s) <NUM> may be disposed in the sensor aperture <NUM> via interference fit. Other configurations of coupling the sensor(s) <NUM> to the mounting bracket <NUM> are contemplated.

In some examples, the sensor aperture(s) <NUM> defines a sensor area <NUM> bounded by a sensor aperture perimeter <NUM>, with the sensor area <NUM> being less than the total mounting area <NUM> of the mounting portion <NUM>. In some examples, the sensor aperture(s) <NUM> is (are) spaced from the perimeter <NUM> of the mounting portion <NUM> (i.e., a portion of the total mounting area <NUM> is disposed between the sensor aperture <NUM> and the perimeter <NUM> of the mounting portion <NUM>). It should be appreciated that in addition to the seal <NUM> described below, the sensor mounting system <NUM> may further include a sensor perimeter seal coupled to the mounting bracket <NUM> and comprised of the second plastic material (described below) and configured to engage the mounting surface <NUM> to inhibit debris, dust, moisture, and the like from entering the sensor aperture <NUM>.

In configurations where the sensor mounting system <NUM> is configured to support more than one sensor <NUM>, the mounting bracket <NUM> defines a plurality of sensor apertures <NUM> configured to support respective sensors <NUM> such that the sensors <NUM> are concealed within the confines of the seal <NUM> (described below). It is to be appreciated that the sensor mounting system <NUM> may be configured to support any number of sensors <NUM>, such as two, three, four, five, six, or more sensors <NUM>. For example, the mounting portion <NUM> may define a first sensor aperture housing a camera, a second sensor aperture for housing a rain sensor, a third aperture for housing a light sensor, and a fourth aperture for housing a LIDAR sensor. In some examples, a single sensor aperture <NUM> may be configured to support a plurality of sensors <NUM>. Additionally, in configurations where the sensor mounting system <NUM> is included in a window assembly <NUM>, the mounting portion <NUM> defines a notch <NUM> sized to receive a mirror button for securing a rearview mirror <NUM> to the transparent pane <NUM>.

The sensor mounting system <NUM> also includes a seal <NUM>. The seal <NUM> is comprised of a second plastic material, different than the first plastic material of the mounting bracket <NUM>. In these embodiments, the second plastic material has an elastic modulus of <NUM> MPa or less. The second plastic material may additionally or alternatively have a Shore A hardness of <NUM> or less. In some examples, the second plastic material is a thermoplastic elastomer, which may be further defined as thermoplastic urethane, but other materials are contemplated.

As best shown in <FIG>, the seal <NUM> is coupled to the mounting bracket <NUM>. Here, the seal <NUM> extends away from the mounting portion <NUM> such that the seal <NUM> is configured to engage the mounting surface <NUM> (e.g. the inner surface <NUM> of the transparent pane <NUM>) to inhibit ingress of debris, dust, moisture, and the like in the space between the mounting surface <NUM> and the mounting bracket <NUM> (e.g. the total mounting area <NUM> of the mounting portion <NUM>). The seal <NUM> extends along the perimeter <NUM> of the mounting portion <NUM> of the mounting bracket <NUM> (best shown in <FIG>). It should be appreciated that in some embodiments, such as shown in <FIG>, the seal <NUM> extends along the entire perimeter <NUM> of the mounting portion <NUM> of the mounting bracket <NUM>. However, in other embodiments, the seal <NUM> may extend partially along the perimeter <NUM> (e.g. one side) of the mounting portion <NUM> of the mounting bracket <NUM>. Having the seal <NUM> extend along the perimeter <NUM> of the mounting portion <NUM> and configured to engage the mounting surface <NUM> inhibits debris, dust, moisture, and the like from not only entering the total mounting area <NUM>, but also from entering the sensor aperture(s) <NUM>. Additionally, having the seal <NUM> configured to engage the mounting surface <NUM> reduces vibrations between the mounting bracket <NUM> and the mounting surface <NUM> and also reduces noise, vibration, and harshness (NVH) that may arise between the mounting bracket <NUM> to the mounting surface <NUM> of the vehicle <NUM>.

A variety of approaches for coupling the seal <NUM> to the mounting bracket <NUM> are contemplated. For example, the seal <NUM> may be overmolded over the mounting bracket <NUM>. The mounting bracket <NUM> and the seal <NUM> may be formed through two shot injection molding. Specifically, the mounting bracket <NUM> may be injection molded with the first plastic material and then the seal <NUM> including the second plastic material may be injection molded over the mounting bracket <NUM>. In other words, the mounting bracket <NUM> may be formed from a first injection molding operation, and the seal <NUM> may be formed from a second injection molding operation, subsequent to first injection molding operation, such that the seal <NUM> is overmolded to the mounting bracket <NUM>. In these examples, it is important to select the first plastic material and the second plastic material to be compatible for an overmolding process. In some examples, such as shown in <FIG>, the mounting bracket <NUM> defines a bracket channel <NUM>. In some examples, the seal <NUM> is at least partially disposed in the bracket channel <NUM>. For example, the seal <NUM> may overmolded into the bracket channel <NUM> or press-fit into the bracket channel <NUM> to couple the seal <NUM> to the mounting bracket <NUM>. Other configurations of coupling the seal <NUM> to the mounting bracket <NUM> are contemplated.

Referring to <FIG>, the sensor mounting system <NUM> may further include a cover <NUM> coupled to the mounting bracket <NUM>. Although not required, the cover <NUM> may conceal the sensor <NUM>. The cover <NUM> may be fastened to the mounting bracket <NUM> (e.g. via screws, clips, or the like), or the cover <NUM> may be coupled to the mounting bracket <NUM> via interference fit. Other configurations of coupling the cover <NUM> to the mounting bracket <NUM> are contemplated. When present, the cover <NUM>, when coupled to the mounting bracket <NUM>, extends away from the mounting surface <NUM>. For example, referring to <FIG>, in configurations where the sensor mounting system <NUM> is included in a window assembly <NUM>, the mounting bracket <NUM> is disposed between the inner surface <NUM> of the transparent pane <NUM> and the cover <NUM>. The cover <NUM> is typically referred to as a beauty cover. As shown in the illustrated configurations, where the sensor mounting system <NUM> is included in a window assembly <NUM>, the cover <NUM> may define a through-hole <NUM> for receiving supporting a rear view mirror <NUM>.

In one embodiment, the seal <NUM> is further defined as a first seal <NUM>, and the sensor mounting system <NUM> may include a second seal <NUM>. The second seal <NUM> is interposed between the mounting bracket <NUM> and the cover <NUM>, as shown in <FIG>. In other words, the second seal <NUM> is coupled to one of the mounting bracket <NUM> and the cover <NUM> and arranged to abut the other of the mounting bracket <NUM> and the cover <NUM> to inhibit debris, dust, moisture, and the like, from entering therebetween. The second seal <NUM>, like the first seal <NUM>, may be formed from the second plastic material. A variety of approaches for coupling the second seal <NUM> to one of the mounting bracket <NUM> and the cover <NUM> are contemplated. In some examples, referring to <FIG>, the mounting bracket <NUM> has a coupling portion <NUM> facing opposite the mounting portion <NUM>, and the second seal <NUM> may disposed around a perimeter <NUM> of the coupling portion <NUM>. In other examples, the second seal <NUM> is overmolded over one of the mounting bracket <NUM> and the cover <NUM>.

In another embodiment, another mounting system <NUM> according to the present disclosure is generally shown in <FIG>. Similar to the sensor mounting system <NUM> described above in the context of <FIG>, the sensor mounting system <NUM> is configured to house a sensor <NUM> relative to a mounting surface <NUM> of a vehicle <NUM>. Here, the mounting system <NUM> may also be referred to as "sensor mounting system <NUM>". In these examples, the mounting surface <NUM> of the vehicle <NUM> includes, for example, a pillar of the vehicle <NUM>, such as an A-Pillar, B-Pillar, or C-Pillar, or otherwise to the exterior of the vehicle. Similar to the sensor <NUM> described above in the context of <FIG>, the sensor <NUM> may be a camera, rain sensor, light sensor, light detection and ranging (LIDAR) sensor, collision sensor, forward collision sensor, and like, or combinations thereof, and the sensor mounting system <NUM> may have more than one sensor <NUM>.

With continued reference to <FIG>, the sensor mounting system <NUM> includes a mounting bracket <NUM> comprised of the first plastic material (described above). The mounting bracket <NUM> has a mounting portion <NUM> that is configured to be coupled to the mounting surface <NUM> of the vehicle <NUM>, such as sheet metal of the vehicle and/or to the material that is behind an A-Pillar, B-Pillar, C-Pillar, etc. The mounting portion <NUM> defines a total mounting area <NUM> bounded by a perimeter <NUM> of the mounting portion <NUM>. Similar to as described above in the context of <FIG>, the mounting portion <NUM> defines one or more sensor apertures <NUM> within the perimeter <NUM> of the mounting portion <NUM>. The mounting bracket <NUM> is configured to support the sensor(s) <NUM> such that the sensor(s) <NUM> are aligned with a respective sensor aperture <NUM>. The sensor(s) <NUM> is (are) typically removably coupled to the mounting bracket <NUM>. For example, the sensor(s) <NUM> may be fastened to the mounting bracket <NUM> (e.g. via screws, clips, or the like), or the sensor(s) <NUM> may be disposed in the sensor aperture <NUM> via interference fit. Other configurations of coupling the sensor(s) <NUM> to the mounting bracket <NUM> are contemplated.

The sensor mounting system <NUM> also includes a seal <NUM> comprised of the second plastic material (described above). Similar to as described above in the context of <FIG>, a variety of approaches for coupling the seal <NUM> to the mounting bracket <NUM> are contemplated. For example, similar to as described above in the context of <FIG>, the mounting bracket <NUM> may define a bracket channel (not shown) for receiving the seal <NUM>.

In the present configurations, the seal <NUM> extends away from the mounting portion <NUM> such that the seal <NUM> is configured to engage the mounting surface <NUM> of the vehicle <NUM> (e.g. the sheet metal of the vehicle <NUM> and/or to the material that is behind an A-Pillar, B-Pillar, C-Pillar, etc.) to inhibit ingress of debris, dust, moisture, and the like in the space between the mounting surface <NUM> and the mounting bracket <NUM>. Having the seal <NUM> configured to engage the mounting surface <NUM> of the vehicle <NUM> to inhibit ingress of debris between the mounting portion <NUM> and the mounting surface <NUM> of the vehicle <NUM> inhibits debris from not only entering the space between the mounting surface <NUM> and the mounting bracket <NUM>, but also from entering the sensor aperture(s) <NUM>.

With particular reference to <FIG> and <FIG>, similar to as described above in the context of <FIG>, the sensor mounting system <NUM> may also include an exterior cover <NUM>. <FIG> shows the mounting bracket <NUM> rotated approximately <NUM> degrees from the view of <FIG>. In other words, the mounting portion <NUM> shown in <FIG> is coupled to mounting surface <NUM> the vehicle <NUM>, and the exterior cover <NUM> is facing the exterior of the vehicle <NUM> with the sensor <NUM> viewing the exterior of the vehicle <NUM> through the exterior cover <NUM> (illustrated schematically with reference numeral <NUM>). In some examples, at least the portion <NUM> of the exterior cover <NUM> that is aligned with the field of view (FOV) of the sensor <NUM> may be transparent. In these examples, the exterior cover <NUM> may comprise glass or a transparent polymeric material, such as described above in the context of transparent pane <NUM>. The exterior cover <NUM> may also include an opaque mask <NUM> disposed on portions of the exterior cover <NUM> that are not aligned with the field of view FOV of the sensor <NUM> to conceal any components beneath the exterior cover <NUM>.

The present disclosure is also directed to a method <NUM> of forming the window assembly <NUM> according to the present disclosure. Referring to <FIG>, the method <NUM> includes a step <NUM> of providing a transparent pane <NUM> having an inner surface <NUM> and an opposing outer surface <NUM>. The method <NUM> of forming the window assembly <NUM> also includes a step <NUM> of forming a mounting bracket <NUM> having a mounting portion <NUM> defining a total mounting area <NUM> bounded by a perimeter <NUM> of the mounting portion <NUM>. The mounting portion <NUM> further defines a sensor aperture <NUM> within the perimeter <NUM> of the mounting portion <NUM>. Similar to as described above, the mounting bracket <NUM> is comprised of a first plastic material having at least one of an elastic modulus of <NUM> MPa or greater and a Shore D hardness of <NUM> or greater. The method <NUM> further includes a step <NUM> of coupling a seal <NUM> to the mounting bracket <NUM> along the perimeter <NUM> of the mounting portion <NUM>. Similar to as described above, the seal <NUM> is comprised of a second plastic material, different than the first plastic material, and having at least one of an elastic modulus of <NUM> MPa or less and a Shore A hardness of <NUM> or less. In some examples, the step <NUM> may further include overmolding the seal <NUM> over the mounting bracket <NUM> along the perimeter <NUM> of the mounting portion <NUM>. The method <NUM> additionally includes a step <NUM> of coupling the mounting bracket <NUM> to the inner surface <NUM> of the transparent pane <NUM> (e.g. via an adhesive, directly or indirectly) such that the seal <NUM> engages the inner surface <NUM> of the transparent pane <NUM> to inhibit ingress of debris between the mounting portion <NUM> and the inner surface of the transparent pane <NUM>.

Several embodiments have been described in the foregoing description. However, the embodiments described herein are not intended to be exhaustive or limit the invention to any particular form. The terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations are possible in light of the above teachings and the invention may be practiced otherwise than as specifically described.

Claim 1:
A window assembly (<NUM>) configured to house a sensor (<NUM>), the window assembly (<NUM>) comprising:
a transparent pane (<NUM>) including an inner surface (<NUM>) and an opposing outer surface (<NUM>);
a mounting bracket (<NUM>) including a mounting portion (<NUM>) coupled to the inner surface (<NUM>) of the transparent pane (<NUM>) via an adhesive, the mounting portion (<NUM>) defining a total mounting area (<NUM>) bounded by a perimeter (<NUM>) of the mounting portion (<NUM>), and defining a sensor aperture (<NUM>) within the perimeter (<NUM>) of the mounting portion (<NUM>), wherein the mounting bracket (<NUM>) comprises a first plastic material having at least one of an elastic modulus of <NUM> MPa or greater and a Shore D hardness of <NUM> or greater, and wherein the mounting bracket (<NUM>) is configured to support the sensor (<NUM>) such that the sensor (<NUM>) is aligned with the sensor aperture (<NUM>); and
a seal (<NUM>) coupled to the mounting bracket (<NUM>) along the perimeter (<NUM>) of the mounting portion (<NUM>) and engaging the inner surface (<NUM>) of the transparent pane (<NUM>) to inhibit ingress of debris between the mounting portion (<NUM>) and the inner surface (<NUM>) of the transparent pane (<NUM>), wherein the seal (<NUM>) comprises a second plastic material, different than the first plastic material, and having at least one of an elastic modulus of <NUM> MPa or less and a Shore A hardness of <NUM> or less.