Low-Profile Inside Mirror Mount Using Adhesive Ball Stud Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rearview mirrors require thick and heavy housings due to the need for screws to secure the ball stud to the socket, which increases manufacturing time and cost, and results in vibrations leading to image blurriness.
Innovation Solution
Adhesively attaching either the ball stud or socket to the rear surface of the substrate, eliminating the need for screws and allowing for a thinner, lighter mirror assembly with reduced vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws are used to secure the ball stud to the socket, then the mounting mechanism is firmly fixed, but the housing becomes thick and heavy
Solution Approach 1:
The patent replaces the mechanical screw-fastening system with an adhesive bonding system. The adhesive layer chemically bonds the ball stud to the socket, eliminating the need for mechanical fasteners and the associated thick housing structure required to accommodate screws and washers.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical (screws) to chemical (adhesive), fundamentally altering how the components are joined. This parameter change allows for a thinner, lighter housing while maintaining adequate mounting strength for the mirror assembly.
2Strength
If screws are used to secure the ball stud to the socket, then the mounting mechanism is firmly fixed, but the manufacturing time and cost increase
Solution Approach 1:
The adhesive bonding system replaces the multi-step mechanical assembly process involving screws, washers, and torque specifications with a simpler application process. The adhesive can be applied and components bonded in fewer steps, reducing manufacturing cycle time and labor costs.
Solution Approach 2:
The patent extracts and eliminates the screw, washer, and associated fastening hardware from the assembly process. This removal of components simplifies the manufacturing process, reduces part inventory requirements, and decreases assembly time.
3Strength
If a thick housing is used to accommodate screw mounting, then the mounting mechanism is secure, but vibrations occur leading to image blurriness
Solution Approach 1:
The adhesive bonding system creates a more uniform and compliant connection between the ball stud and socket compared to rigid mechanical fastening. This reduces stress concentrations and vibration transmission, minimizing image blurriness while maintaining mounting security.
Solution Approach 2:
The use of adhesive material creates a composite bonding structure that combines the rigidity needed for secure mounting with the damping properties of the adhesive layer itself, which absorbs vibrations and prevents their transmission to the mirror element.
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 solution reduces the mirror's profile thickness and weight, minimizing vibrations and image blurriness while simplifying assembly and reducing manufacturing costs.
Implementation Method 1
one of the ball stud and the socket is adhesively attached to the rear surface of the substrate
Data Source
AI summary
A rearview mirror assembly for a vehicle is provided, including: a mirror element having at least one substrate including a front surface and a rear surface; a mounting mechanism configured to be mounted to the vehicle, the mounting mechanism including a ball stud and a socket for receiving a ball of the ball stud, wherein the mounting mechanism is further configured such that one of the ball stud and the socket is adhesively attached to the rear surface of the substrate; and a mirror housing secured to the mirror element so as to extend behind the rear surface of the substrate and around the one of the ball stud and the socket that is attached to the rear surface.