HUD Mirror Holder Alignment for Precise Image Calibration

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Solution Overview

Problem

Conventional head up display systems face challenges in achieving precise mirror rotation and image accuracy due to the use of extended arms or levers for switch actuation, which increases tolerance stack-up and complicates manufacturability, and are prone to breaking during handling and assembly.

Innovation Solution

A self-centering mirror holder with a rotational axis-aligned design and integrated activation features, utilizing a cylindrical shape with a conical self-centering feature and high lubricity polymer, eliminates the need for external arms or levers, allowing precise calibration and reduced tolerance stack-up, and enhances durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an extended arm or lever is used to connect the mirror holder and switch, then the activation face is removed from the rotational axis, but this increases the proximity to the limit switch and results in increased tolerance stack up which diminishes image accuracy

Engineering Contradiction:

Improveswitch actuationVSAvoidimage accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent removes the extended arm or lever component from the mirror holder assembly, directly connecting the activation face to the rotational axis. This extraction eliminates the intermediate mechanical linkage that caused tolerance accumulation, allowing the limit switch to be positioned with minimum proximity to the activation feature while maintaining accurate image positioning.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mirror holder is designed with distinct functional segments: the activation feature aligned with the rotational axis, the mirror mounting portion, and the limit switch positioning. This segmentation allows each component to be optimized independently, with the activation face directly on the rotational axis for precision and the limit switch positioned separately for calibration functionality.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If an extended arm or lever is used for switch actuation, then the mirror holder can be actuated, but this complicates the manufacturability of the mirror holder

Engineering Contradiction:

Improveswitch actuationVSAvoidmirror holder manufacturability

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The extended arm or lever is completely removed from the design, simplifying the mirror holder to a more manufacturable form. The activation feature is integrated directly into the holder body at the rotational axis, eliminating complex mechanical linkages that would complicate manufacturing processes and increase production complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The activation feature is merged with the mirror holder body itself, with the activation face positioned directly on the rotational axis. This integration eliminates the need for separate arms or levers, reducing the number of parts and simplifying the manufacturing process while maintaining full actuation functionality.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If an extended arm or lever is used in the mirror holder, then switch actuation is achieved, but this increases the risk of breaking during handling and assembly

Engineering Contradiction:

Improveswitch actuationVSAvoiddurability during handling

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The vulnerable extended arm or lever is removed from the design, eliminating the component that was prone to breaking during handling and assembly. The mirror holder is redesigned with a compact structure where the activation feature is integrated into the main body, removing weak points that could fail under mechanical stress.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of extending the activation mechanism outward with a vulnerable arm or lever, the design inverts the approach by positioning the activation face directly on the rotational axis within the holder body. This reverses the traditional configuration, placing the activation feature where it is structurally strongest and least susceptible to damage during handling.

Inventive Principle:

Principle #13The other way round (Inversion)

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 improves mirror position accuracy, simplifies manufacturability, reduces scrap rates, and maintains precise image positioning without the need for additional lubricants or complex assembly components.

Implementation Method 1

high lubricity polymer

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

cylindrical shape with a conical self-centering feature

Methodology Applied

Scientific EffectGeometric constraint: Geometry

Data Source

PatentUS11860362B2Hud mirror holder and image positional accuracy design

Publication Date: 2024.01.02 PANASONIC AUTOMOTIVE SYSTEMS AMERICA LLC

AI summary

A head up display mirror holder arrangement for a motor vehicle includes a picture generation unit producing a light field. A mirror reflects the light field such that the light field is visible to the driver as a virtual image. A mirror holder has two opposite ends and an activation feature. The two opposite ends are aligned along a rotational axis of the mirror. The mirror holder retains the mirror. Each of two bushings is coupled to a respective opposite end of the mirror holder. A calibration switch has minimum proximity to the activation feature of the mirror holder.