Asymmetric Chamfer Aspheric Mirror for HUD Edge Distortion
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Solution Overview
Problem
HUD systems suffer from poor optical quality due to mirror imperfections, leading to decreased safety and usability, as blurry images can increase user processing time and distraction.
Innovation Solution
The development of a mirror with an asymmetrical chamfer design for improved edge distortion reduction, using a vacuum-based forming method with a ditch-type vacuum hole to minimize manufacturing artifacts and enhance surface accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional mirror is used in the HUD system, then the system structure is simple, but the optical quality of the projected image is poor
Solution Approach 1:
The patent applies asymmetry by introducing a chamfer at the edge of the mirror substrate that is asymmetric relative to the optical axis. This asymmetric chamfer structure specifically targets and reduces edge distortion in the projected image, improving optical quality without requiring complete redesign of the entire mirror system.
Solution Approach 2:
The patent applies local quality by implementing the chamfer only at the edge region of the mirror substrate where distortion occurs, rather than modifying the entire mirror surface. This localized modification addresses the specific problem of edge distortion while maintaining the simplicity of the overall mirror structure.
2Manufacturing precision
If vacuum-based forming method is used to improve surface accuracy, then manufacturing precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies pneumatics by using vacuum-based forming methodology to form the mirror substrate. The vacuum pressure is applied through strategically positioned vacuum holes to achieve precise surface accuracy and create the desired asymmetric chamfer geometry, improving manufacturing precision through controlled pneumatic pressure distribution.
Solution Approach 2:
The patent applies segmentation by dividing the vacuum pressure application into multiple discrete vacuum holes positioned at specific locations on the mold. This segmented approach to vacuum application allows for precise control of the forming process, enabling complex asymmetric chamfer geometries to be achieved through coordinated activation of individual vacuum zones.
3Manufacturing precision
If edge distortion is reduced through asymmetric chamfer, then optical performance at edge is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies asymmetry by designing the chamfer geometry to be asymmetric relative to the optical axis, with different chamfer dimensions on opposite sides of the mirror. This asymmetric configuration specifically counteracts the symmetric edge distortion that occurs in conventional circular mirrors, improving optical performance at the edges through geometric compensation.
Solution Approach 2:
The patent applies preliminary action by incorporating the asymmetric chamfer into the mirror substrate during the initial vacuum forming process, rather than adding it as a separate post-processing step. This preliminary integration of the distortion-correcting geometry simplifies the overall manufacturing process despite the increased geometric complexity.
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 results in improved optical performance at the edge of the mirror, reducing image distortion and enhancing user safety by providing clearer, more readable information without distracting light entry.
Implementation Method 1
conforming the glass-based preform to the curved support surface
Data Source
Figure 1~3
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Figure 7A~8A
AI summary
A glass-based preform for a mirror of a heads-up display (HUD) system, including a glass-based substrate having a first major surface, a second major surface opposite to the first major surface, and a minor surface connecting the first and second major surfaces; a first chamfer at an edge of the first major surface, the first chamfer having a first end at an intersection of the first chamfer and the first major surface and having a second end at an intersection of the first chamfer and the minor surface; and a second chamfer at an edge of the second major surface, the second chamfer having a first end at an intersection of the second chamfer and the second major surface and having a second end at an intersection of the second chamfer and the minor surface. The first chamfer has a different size or shape from the second chamfer.