Integrated Bracket Design Optimizations to Resolve Issues in Vehicle Prototype Stage

Integrated bracket is a plastic part which packages functional components such as ADAS, Rain Light Sensor and the mounting provisions of auto dimming IRVM. This part is fixed on the windshield of an automobile using double sided 3M tapes and glue. ADAS, rain light sensor and auto dimming IRVM play an important part in the safety of driver, and everyone present in the automobile. The paper takes the readers through a concern faced by the authors that emphasizes the importance of the combination and location of tapes and glues on the integrated bracket. The 3M tapes at the B side of the integrated bracket are used to locate it on the windshield and hold it until the glue's curing time gets completed. If the combination and positions of glue and tapes is not optimum, then the bracket will get peeled off from the windshield causing aesthetic deterioration. This concern came in the prototype stage of a Mahindra SUV. In this concern, the integrated bracket was peeling off from the windshield all over its edges. It was reported on all vehicles of the prototype stage. In the root cause analysis it was clear that this concern was related to the features provided at the B side of the bracket to package the 3M tapes and glue. The immediate corrective action to be implemented immediately for all prototype vehicles was additional tapes on the edges of the integrated bracket. While the number of concerns were reduced, the concern still remained. After that, design changes were done to make the most optimum combination and location of tapes and glue. This paper takes through the findings of root cause analysis done by authors and design optimizations accommodated to solve the peeling off concern of integrated bracket.