Electrochromic Mirror Assembly With Rounded Edges and Hidden Connectors
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Solution Overview
Problem
Existing rearview mirror assemblies face challenges in achieving a curved transition between the mirror casing and the reflective element while maintaining regulatory compliance and minimizing weight, particularly in ensuring the electrical connections do not disrupt the continuous curved edge.
Innovation Solution
The solution involves a laminate construction with a front and rear glass substrate, both having curved or rounded perimeter edges, where the rear substrate is nested within the casing, and electrical connections are made through cutouts and protrusions to maintain a continuous curved edge while allowing for electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical connectors are established at the rear of the reflective element, then electrical connectivity is achieved, but the continuous curved edge is disrupted
Solution Approach 1:
The electrical connectors are extracted and positioned at the rear of the reflective element, separated from the front curved edge. This allows the front to maintain its continuous curved aesthetic while the rear accommodates the necessary electrical connection points for the electrochromic technology.
Solution Approach 2:
The reflective element is segmented into distinct functional zones: the front curved edge portion for aesthetic purposes and the rear portion for electrical connectivity. This segmentation allows each portion to optimize its specific function without compromising the other.
2Shape
If the rear substrate is nested in the mirror casing, then a curved transition is achieved, but manufacturing complexity increases
Solution Approach 1:
The rear substrate is nested within the mirror casing, with the front substrate extending beyond it to form the curved transition. This nested arrangement allows the curved aesthetic to be achieved while keeping the overall assembly compact and manageable.
Solution Approach 2:
The curved transition geometry is predetermined in the design of the front and rear substrates, allowing for pre-manufacturing of the curved portions before final assembly. This reduces on-site manufacturing complexity while maintaining the desired aesthetic.
3Shape
If both front and rear substrates have rounded perimeter edges, then aesthetic continuity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The rounded perimeter edges are applied locally to specific regions of the front and rear substrates where aesthetic continuity is required, rather than uniformly across all edges. This allows for focused precision work on the visible curved transition areas while reducing overall manufacturing 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
This design achieves a smooth, curved transition between the mirror casing and the reflective element, meets regulatory requirements for exposed edges, and allows for efficient electrical connectivity without compromising the continuous curved edge, thereby enhancing the aesthetic and functional aspects of the rearview mirror assembly.
Implementation Method 1
a variable reflectance electro-optic mirror reflective element
Data Source
AI summary
A method for assembling an electrochromic mirror reflective element includes providing front and rear glass substrates, disposing a transparent electrically conductive coating at a second surface of the front glass substrate, and disposing an electrically conductive coating at a third surface of the rear glass substrate. The front and rear glass substrates are joined via a perimeter seal and an electrochromic medium is disposed within an interpane cavity established between the front glass substrate and the rear glass substrate and bounded by the perimeter seal. With the front glass substrate joined with the rear glass substrate, and with the electrochromic medium disposed within the interpane cavity, the first and second perimeter edges are ground to round the first and second perimeter edges to provide a rounded perimeter edge of the electrochromic mirror reflective element that has a radius of curvature of at least 2.5 mm.