Electrochromic Rearview Mirror Perimeter Layout for Uniform Electrification
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Solution Overview
Problem
Existing electrochromic rearview mirror assemblies face challenges with solvent escape and uneven electrification due to the interaction of the main seal and conductive epoxy, leading to voids and non-uniform electrical conductivity.
Innovation Solution
The implementation of a zigzag or wavy pattern for the electrically conductive material along the perimeter edge of the glass substrates in the electrochromic mirror assembly, allowing solvent venting and ensuring uniform electrification by maintaining gaps between the conductive material and the rear glass substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive epoxy is applied along the perimeter edge region to provide electrical connection, then electrical conductivity is improved, but solvent bubbles are trapped causing voids and non-uniform electrical conductivity
Solution Approach 1:
The conductive epoxy is applied in a zigzag pattern rather than a continuous line, segmenting the material application into discrete sections. This segmentation creates intentional gaps that allow solvent to escape during curing, preventing bubble entrapment while maintaining electrical conductivity through the segmented conductive paths
Solution Approach 2:
The zigzag pattern is designed in advance to anticipate and prevent solvent entrapment issues. By pre-planning the gaps in the conductive material path, the design allows solvent to vent during the curing process before voids can form, ensuring uniform electrical conductivity from the start
2Reliability
If continuous conductive material is applied along the perimeter edge, then electrical connection is ensured, but solvent escape is blocked causing voids and non-uniform electrification
Solution Approach 1:
The conductive epoxy application is segmented into a zigzag pattern with intentional gaps, allowing solvent to escape during curing while maintaining electrical connectivity through the segmented conductive paths. This resolves the conflict between ensuring electrical connection and allowing solvent escape
Solution Approach 2:
The conductive epoxy is applied with different characteristics at different locations - continuous in some areas to ensure electrical connection, and discontinuous (with gaps) in other areas to allow solvent escape. This local variation in application quality achieves both electrical reliability and manufacturing precision
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 effectively prevents solvent bubbles and ensures uniform electrical conductivity, enhancing the reliability and performance of the electrochromic mirror assembly.
Implementation Method 1
The mirror reflective element may comprise an electrochromic mirror reflective element comprising a front glass substrate and a rear glass substrate with an electrochromic medium sandwiched between the glass substrates
Data Source
AI summary
A vehicular electrochromic rearview mirror assembly includes a mounting structure and a mirror head. The mirror head accommodates an electrochromic mirror reflective element including front and rear glass substrates and an electrochromic medium disposed therebetween. The medium conductively contacts a transparent conductive coating at a second side of the front substrate and a conductive coating at a third side of the rear substrate. A conductive connector is disposed at a fourth side of the rear substrate and conductively connects to a conductive material along a perimeter region of the second side and the conductive coating at the third side. The perimeter region extends beyond an outer peripheral edge of the rear substrate. The conductive material is established in a zigzag pattern along the perimeter region so portions of the zigzag pattern are inboard and other portions are outboard of the edge of the rear substrate.