Hybrid Mirror Mounting Assembly Stiffness
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Solution Overview
Problem
Existing side view mirror attachment assemblies for vehicles face challenges in providing sufficient structural stiffness to minimize mirror vibration while being lightweight and cost-effective, as full plastic monoblock base brackets are insufficiently rigid and fully die cast aluminum solutions are heavy and expensive.
Innovation Solution
A hybrid external mirror mounting assembly featuring a polymeric outer shell with strategically placed sheet metal reinforcement elements, where the metal reinforcement core is partially covered by a polymeric material to form three-dimensional form closures, providing structural support and reducing weight compared to fully die cast solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a full plastic monoblock base bracket is used, then the manufacturing cost is reduced and weight is lowered, but the structural stiffness is insufficient leading to visible mirror vibration
Solution Approach 1:
The patent employs a composite structure combining polymeric material for the outer shell and metal reinforcement elements (steel or aluminum) strategically positioned within the polymer to create a hybrid mounting assembly that achieves high stiffness-to-weight ratio
Solution Approach 2:
Metal reinforcement elements are strategically placed only in specific high-stress areas where additional stiffness is needed, rather than using solid metal throughout the entire structure, optimizing the stiffness-to-weight ratio
2Strength
If a fully die cast aluminum carrier is used, then the structural stiffness is sufficient to reduce mirror vibration, but the weight and manufacturing cost increase significantly
Solution Approach 1:
The patent uses a hybrid composite structure with polymeric outer shell and embedded metal reinforcement elements, replacing the fully metal die cast construction while maintaining sufficient stiffness
Solution Approach 2:
The mounting assembly is divided into functional segments: the polymeric outer shell providing overall structure and aesthetics, and discrete metal reinforcement elements providing localized stiffness where needed
3Strength
If a bulky mirror-mounting structure is used to provide sufficient structural rigidity, then the rigidity is improved, but the aerodynamic drag and vibration during vehicle travel increase
Solution Approach 1:
The patent uses a thin polymeric outer shell that provides aerodynamic smoothness and weather protection while the embedded metal reinforcement elements provide the necessary structural rigidity, creating a streamlined profile that reduces aerodynamic drag
4Strength
If long steel screws are used as metallic reinforcements, then the rigidity is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the metal reinforcement elements and polymeric shell into a single integrated hybrid component manufactured in one injection molding process, eliminating the need for separate assembly steps with long steel screws
Data Source
AI summary
An automotive side view mirror attachment assembly includes a polymeric outer shell having a metal reinforcement member coupled thereto, wherein the polymeric outer shell forms form closures about connecting features of the metal reinforcement member, so as to provide an operably coupling between the polymeric outer shell and the metal reinforcing member that is secured by independent connection locations that are effective to support an external mirror assembly in multiple dimensions.