Caseless Rearview Mirror Assembly for Low Vibration and Size
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Solution Overview
Problem
Conventional interior rearview mirror assemblies are bulky and heavy, leading to impaired vibration performance, unattractive size, and manufacturing cost and complexity challenges.
Innovation Solution
The mirror reflective element is pivotally attached to a windshield electronics module, eliminating the need for a mirror housing/casing. A caseless electro-optic rearview mirror assembly features a front transparent glass substrate with a rounded edge, a rear substrate with a rounded edge, and an electro-optic medium sandwiched between them, with control circuitry disposed separate from the mirror element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bulky mirror housing/casing is used to house the electro-optic medium and control circuitry, then the mirror assembly provides structural support and houses all components, but the weight increases and vibration performance deteriorates
Solution Approach 1:
The patent divides the mirror assembly into separate functional components: the electro-optic medium is mounted directly to the windshield, while the control circuitry is housed in a separate module. This segmentation eliminates the need for a bulky housing to contain both components together, reducing overall weight while maintaining structural support through distributed mounting.
Solution Approach 2:
The patent extracts the control circuitry from the traditional mirror housing and places it in a separate module mounted to the windshield. This extraction removes unnecessary structural material, reducing weight and improving vibration performance while the circuitry continues to function independently.
2Reliability
If a bulky mirror housing/casing is used to house all components, then structural support is provided, but the size becomes unattractive and space is wasted
Solution Approach 1:
By segmenting the mirror system into a thin electro-optic medium mounted directly to the windshield and a separate compact control module, the patent eliminates the need for a large housing volume. Each component occupies minimal space at its mounting location, reducing overall assembly volume while maintaining structural support.
Solution Approach 2:
The patent transitions from a three-dimensional bulky housing structure to a predominantly two-dimensional configuration where the electro-optic medium is a thin layer mounted flat against the windshield. This dimensional change dramatically reduces volume while preserving the structural support function through the windshield mounting.
3Ease of manufacture
If a traditional plastic injection molded housing is used, then manufacturing is straightforward, but manufacturing cost and complexity increase
Solution Approach 1:
The patent extracts the control circuitry module from the traditional integrated housing structure. This allows the electro-optic medium to be manufactured as a simple thin-film component mounted directly to the windshield, eliminating complex plastic injection molding operations and reducing overall manufacturing complexity despite requiring separate module assembly.
Solution Approach 2:
The patent changes the manufacturing approach from molding a bulky three-dimensional housing to depositing a thin-film electro-optic medium directly onto the windshield surface. This parameter change in manufacturing technique (from volumetric molding to surface deposition) simplifies the fabrication process and reduces material requirements while achieving the same functional outcome.
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 solution provides a low-profile mirror head with improved vibration performance, reduced size, and lower manufacturing costs, while maintaining effective dimming control of the electro-optic medium.
Implementation Method 1
a caseless electro-optic rearview mirror assembly features a front transparent glass substrate with a rounded edge, a rear substrate with a rounded edge, and an electro-optic medium sandwiched between them
Data Source
AI summary
A vehicular vision system includes a rear-viewing camera disposed at a vehicle and viewing at least rearward of the vehicle. Video images derived from frames of image data captured by a CMOS imaging array of the rear-viewing camera during a driving maneuver are displayed at a video display screen within the vehicle for viewing by a driver of the vehicle. An electro-optic rearview mirror assembly includes an electro-optic mirror reflective element. An electronic control unit (ECU) disposed at the vehicle includes a processor operable to process captured frames of image data. The ECU determines, via processing by the processor of frames of image data captured by the CMOS imaging array of the rear-viewing camera, glaring light emanating from a rearward approaching vehicle rearward of the vehicle. The ECU controls dimming of the electro-optic mirror reflective element based at least on part on the determined glaring light.