Extruded housing for a mirror

Solution Overview

Problem

The existing housings for illuminated mirrors require custom fabrication, leading to lengthy manufacturing processes, increased lead times, and supply chain complexities due to the need for customized metal components with distinct designs for top, bottom, and side components, which complicates the attachment and positioning of light sources and electronics.

Innovation Solution

A housing assembly for illuminated mirrors featuring extruded and cut-to-size side members with interlocking geometry, including corner members with mounting tabs, allowing for standardized components that simplify assembly and provide multiple mounting positions for light sources, reducing the need for custom metal components and streamlining production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If custom fabricated metal components are used for different sized mirrors, then the housing can be customized to specific mirror dimensions and illumination requirements, but the manufacturing lead time increases and production complexity increases

Engineering Contradiction:

Improvecustomization to mirror sizeVSAvoidmanufacturing lead time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The housing is divided into multiple standardized extruded components (side walls, top, bottom) that can be independently manufactured and then assembled. Each component has standardized features like slots and channels that accommodate various mirror sizes through configuration rather than custom fabrication, reducing lead time while maintaining adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The extruded components are designed with universal features such as slots, channels, and mounting positions that can accommodate different mirror sizes and illumination requirements. A single standardized component design serves multiple functions across different mirror configurations, eliminating the need for custom fabrication for each size.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If custom fabricated metal components are used for different sized mirrors, then the housing can be customized to specific mirror dimensions and illumination requirements, but the supply chain and production complexities increase

Engineering Contradiction:

Improvecustomization to mirror sizeVSAvoidsupply chain complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The housing is divided into multiple standardized extruded components (side walls, top, bottom) that can be independently manufactured and then assembled. Each component has standardized features like slots and channels that accommodate various mirror sizes through configuration rather than custom fabrication, reducing lead time while maintaining adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

All housing components are made from the same extruded material with consistent cross-sectional geometry and standardized features. This homogeneity simplifies the supply chain by allowing a single production process and inventory system to serve all mirror sizes, reducing complexity while maintaining customization capability.

Inventive Principle:

Principle #33Homogeneity

3Loss of time

If standardized extruded components are used, then manufacturing lead time is reduced and production is simplified, but the ability to provide customized illumination positions may be limited

Engineering Contradiction:

Improvemanufacturing lead timeVSAvoidlight source positioning flexibility

Core Design Contradiction:

Loss of timeVSAdaptability or versatility

Solution Approach 1:

The extruded components incorporate locally varied features such as slots, channels, and mounting positions at specific locations along the components. These localized features provide customized illumination positions and light source mounting options while the overall component geometry remains standardized for efficient production.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The housing configuration is made dynamic through the modular assembly of standardized components that can be arranged in different configurations. The slots and channels allow light sources to be positioned at various locations depending on the desired illumination pattern, providing flexibility without requiring custom fabrication for each configuration.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20240049895A1Extruded housing for a mirror

Publication Date: 2024.02.15 SEURA INC

AI summary

A housing assembly for an illuminated mirror including a side member including a base wall, a first sidewall, and a second sidewall defining a channel, the base wall including an inner base wall spaced from an outer base wall and defining a first slot, and a corner member including a corner member base wall, an interior sidewall, and an exterior sidewall defining a corner member channel, a first mounting tab projecting from a first end of the corner member base wall, wherein the first mounting tab is configured to be received by the first slot of the side member to interlock the corner member to the side member.