Injection-Molded Rearview Assembly with Integrated Stop Elements
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Solution Overview
Problem
Existing rearview assemblies for motor vehicles are costly to manufacture due to the use of multiple parts made from different materials, such as metal and plastic, in their pivot mechanisms.
Innovation Solution
A structurally simple and cost-effective rearview assembly design featuring a dome-shaped foot with integrated stop elements and a cap nut that provides secure locking and pivoting, utilizing injection molded plastic parts to reduce component count and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple parts made from different materials (metal and plastic) are used in the pivot mechanism, then the reliability and strength of the connection is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The patent combines multiple separate components (metal pin, plastic housing, pressure plate, securing elements) into an integrated injection-molded plastic assembly. The pivot mechanism is formed as a single molded part with integrated features including the bearing surface, stop elements, and locking structures, eliminating the need for separate metal and plastic parts that were previously assembled together.
Solution Approach 2:
The injection-molded plastic component performs multiple functions simultaneously: it provides the bearing surface for rotation, incorporates stop elements to limit rotation range, includes integrated locking features to secure the pivot mechanism, and serves as the housing structure. This multi-functional design replaces what previously required several specialized components made from different materials.
2Strength
If multiple parts made from different materials are used in the pivot mechanism, then the strength and durability are improved, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple separate components (metal pin, plastic housing, pressure plate, securing elements) into an integrated injection-molded plastic assembly. The pivot mechanism is formed as a single molded part with integrated features including the bearing surface, stop elements, and locking structures, eliminating the need for separate metal and plastic parts that were previously assembled together.
Solution Approach 2:
The patent changes the material parameter from traditional metal-construction to plastic-construction for the pivot mechanism. By using high-strength engineering plastics with appropriate mechanical properties, the design achieves sufficient strength while enabling injection molding manufacturing, which is more cost-effective than machining and assembling multiple metal and plastic parts.
3Ease of manufacture
If a minimal number of parts is used, then the production cost and assembly complexity are reduced, but the reliability of the locking mechanism may be compromised
Solution Approach 1:
The patent combines multiple separate components (metal pin, plastic housing, pressure plate, securing elements) into an integrated injection-molded plastic assembly. The pivot mechanism is formed as a single molded part with integrated features including the bearing surface, stop elements, and locking structures, eliminating the need for separate metal and plastic parts that were previously assembled together.
Solution Approach 2:
While reducing the overall number of parts, the patent incorporates functionally segmented features within the single molded component. The locking mechanism includes distinct elements such as separate stop elements, biasing spring features, and engagement protrusions that are molded as integrated features but provide differentiated functions, ensuring reliable operation while maintaining part minimization.
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
The design allows for secure locking and pivoting of the rearview assembly with a minimal number of parts, reducing production costs and simplifying assembly, while eliminating the need for additional components like pressure discs and securing forks.
Implementation Method 1
the cap nut presents a stop for a spring, which extends around the dome
Implementation Method 2
A structurally simple and cost-effective rearview assembly design featuring a dome-shaped foot with integrated stop elements and a cap nut that provides secure locking and pivoting, utilizing injection molded plastic parts
Data Source
AI summary
A rearview assembly for a motor vehicle includes a dome, a foot attachable to the motor vehicle, a head rotatable relative to the foot, the head including at least one base body with a bearing opening for receiving an axis of rotation associated with the foot, where the foot is shaped together with the dome as an injection molded part, the dome includes at least one first stop element for engagement with at least one complementary second stop element of a cap nut screwed onto the dome, the cap nut providing a stop for a spring which extends around the dome, and the cap nut is an injection molded part.