In electric vehicles (EVs), addressing noise, vibration, and harshness (NVH) has become pivotal, especially concerning external wind noise. To reduce wind noise, a door inner belt weatherstrip needs a high contact load, but this can lead to squeaking noise at the glass/weatherstrip interface. This study demonstrates a multidisciplinary design for the weatherstrip to tackle both issues. By increasing ethylene propylene diene monomer and ethylidene norbornene contents in the thermoplastic vulcanizate (TPV) by about 20 % and 70 %, respectively, the compression set was reduced from 35.4 % to 27.6 %. Concurrently, the TPV’s damping properties improved, with a 25 % increase in loss modulus (323 MPa). Coated flocking surface of weatherstrip significantly reduced the friction coefficient by 80 % (from 1.75 to 0.30). In vehicle evaluations, the newly designed weatherstrip reduced the wind noise by 5 dB(A) and eliminated. This approach highlights the potential of multidisciplinary design in optimizing NVH for next-generation vehicles, including autonomous EVs and urban air mobility.
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