Slim Auto-Dimming Mirror with Integrated Ball Pivot
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Solution Overview
Problem
Existing interior rearview mirror assemblies for vehicles lack a slim or reduced thickness design while maintaining adjustable functionality and efficient electrical connectivity for auto-dimming mirror reflective elements.
Innovation Solution
The interior rearview mirror assembly features a slim mirror head with a variable reflectance electro-optic mirror reflective element, integrated electrically conductive elements, and a ball member integrated into the mirror casing, allowing for electrical connection through a mounting structure that pivots for adjustment, enabling direct access to the electrical connector and automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a traditional mirror assembly design is used with separate mounting structure and electrical components, then the assembly is more robust and easier to manufacture, but the mirror head thickness is increased
Solution Approach 1:
The ball member is integrated directly into the mirror casing to form a single-piece construction, eliminating the need for separate mounting brackets or adapters. This merging of the mounting mechanism with the mirror housing reduces the overall thickness while maintaining structural integrity and adjustability functionality.
Solution Approach 2:
The ball member serves dual functions: it provides the pivot mechanism for adjusting the mirror angle and simultaneously acts as the mounting structure for attaching the mirror assembly to the vehicle. This multi-functionality eliminates redundant components and reduces the mirror head thickness.
2Reliability
If electrical components are integrated within the mirror head, then electrical connectivity is improved, but the mirror head thickness increases
Solution Approach 1:
The electrical connector is extracted from the mirror head and positioned externally, allowing it to route through the mounting structure rather than being housed within the mirror head. This extraction maintains reliable electrical connectivity while preserving the slim profile of the mirror head.
Solution Approach 2:
The mounting structure serves as an intermediary pathway for the electrical connector, allowing electrical signals to reach the mirror reflective element without requiring the connector to be positioned within the mirror head. This mediator approach enables thin mirror head design while maintaining electrical connectivity.
3Adaptability or versatility
If multiple separate components are used for mounting and adjustment, then the assembly is more adjustable and versatile, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The ball member is formed as an integral part of the mirror casing through injection molding, creating a one-piece construction that eliminates the need for separate mounting brackets, adapters, or fasteners. This merging simplifies manufacturing while maintaining full adjustability through the ball-and-socket pivot mechanism.
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
This design achieves a thinner mirror head with improved assembly simplicity and cost-effectiveness, ensuring reliable electrical connectivity and efficient control of the mirror's reflectance, enhancing the vehicle's rearview functionality.
Implementation Method 1
The mirror reflective element may comprise an electrically variable reflectance mirror reflective element, such as an electro-optic (such as electrochromic) variable reflectance mirror reflective element, where reflectance of the mirror reflective element is controlled via electrical current to the mirror reflective element
Data Source
AI summary
A vehicular interior rearview mirror assembly includes a mounting base having a socket, and a mirror head attached at and pivotable about the mounting base. The mirror head includes a variable reflectance electro-optic mirror reflective element, and a ball member that forms a pivot joint with the socket. The mirror reflective element is attached at an attachment plate that includes electrically conductive elements that are electrically connected to respective electrically conductive contacts at the rear side of the mirror reflective element via a connector portion of each electrically conductive element engaging and flexing and being biased toward the respective electrically conductive contact. The electrically conductive elements are electrically connected to a connector of the ball member. With the mounting base mounted at the interior portion of the vehicle and the ball member received in the socket of the mounting base, the connector is electrically connected to a vehicle wire harness.