Head-Up Display Mirror Assembly With Elastic Positioning
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Solution Overview
Problem
Existing head-up display assemblies face issues with positional tolerances and unwanted movements of mirrors due to long tolerance chains and material expansion, leading to image distortion, noise, and flickering, which are not adequately addressed by current snap-fit or adhesive bonding methods.
Innovation Solution
A method involving elastic compression elements attached to the mirror's edges, allowing preassembly and final assembly positioning, with indirect contact to supporting surfaces, ensuring precise and damped support, and controlled movement during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If snap connection or adhesive bonding is used to fasten the mirror to the optical chamber, then the mirror can be secured in position, but long tolerance chains cause mirror tilt resulting in incorrect virtual image position
Solution Approach 1:
The patent introduces an intermediary optical chamber component with a recess that directly receives and positions the mirror. This intermediary structure eliminates the need for long tolerance chains by providing a direct mechanical interface between the mirror mounting and the housing, thereby securing mirror position stability while maintaining virtual image position accuracy.
2Reliability
If adhesive bonding is used to attach the mirror to the optical chamber, then the mirror can be secured, but curvature of the mirror occurs due to different coefficients of expansion of materials, causing image distortion
Solution Approach 1:
The patent replaces adhesive bonding with a mechanical retention system where the optical chamber recess directly holds the mirror in position. This mechanical system eliminates the thermal expansion issues inherent in adhesive bonding between dissimilar materials, thereby maintaining both mirror position stability and image representation accuracy without material curvature.
3Ease of manufacture
If snap-fit connection is used to fasten the mirror, then assembly is simple, but tolerances occur leading to positional deviations and rattling during service life
Solution Approach 1:
The patent segments the optical chamber into a housing portion with an integrated recess that specifically receives the mirror. This segmentation provides a dedicated positioning feature that maintains mirror position accuracy while preserving assembly simplicity, eliminating the rattling and positional deviations associated with conventional snap-fit connections.
4Manufacturing precision
If precise arrangement of mirrors is performed manually, then sharp image representation can be achieved, but assembly complexity increases and productivity decreases
Solution Approach 1:
The patent incorporates preliminary positioning features directly into the optical chamber recess design, where the mirror is pre-positioned in the correct orientation and location before final assembly. This preliminary action ensures sharp image representation through precise mirror arrangement while maintaining high assembly speed by eliminating complex manual positioning steps.
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 method enables precise and stable positioning of mirrors, reducing image distortion and noise, while allowing for easy assembly and vibration damping, ensuring a high-quality image representation.
Implementation Method 1
attaching a first, elastic compression element to a first edge region of a rear side of the first mirror and attaching a second, elastic compression element to a second edge region of the rear side of the first mirror; introducing the first mirror with the compression elements arranged thereon into a cover module of a housing of the head-up display and setting a preassembly position of the first mirror in the cover module, in which the compression elements rest against supporting surfaces of the cover module
Implementation Method 2
as the base module continues to be joined to the cover module, the first mirror is pressed into a final assembly position, wherein, for this purpose, the compression elements are compressed and the first mirror is pressed against the supporting surfaces of the cover module
Data Source
AI summary
The invention relates to a method for assembling a head-up display (1), comprising the following steps: —attaching a first, resilient compression element (18) to a first edge region (16) of a rear face (14) of the first mirror (13) and attaching a second, resilient compression element (19) to a second edge region (17) of the rear face (14) of the first mirror (13); —introducing the first mirror (13) into a cover module (3) of a housing (2) of the head-up display (1) and adjusting a pre-assembly position of the first mirror (13) in the cover module (3), in which position the compression elements (18, 19) abut support surfaces (27, 28) of the cover module (3); —attaching a base module (6) to the cover module (3), wherein, during the connection process, a front face (15) of the first mirror (13) is contacted by contact elements (23, 24) of the base module (6) and the first mirror (13) is pressed into a final assembly position.