Micro-LED Rearview Mirror Assembly Without Reflector Masking
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Solution Overview
Problem
Existing vehicle mirror systems for blind spot detection and turn signal indication require complex masking techniques and modifications to the reflector, which can increase manufacturing costs and complexity.
Innovation Solution
A rearview mirror assembly with a micro-LED lighting subassembly that projects light through the mirror element using a diffuser and micro light-emitting diodes arranged in specific shapes, eliminating the need for masking layers and allowing for integrated heating elements, thus simplifying the design and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex masking techniques and reflector modifications are used for blind spot detection indication, then the indication function is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines the blind spot detection indicator with the turn signal indicator into a single integrated lighting subassembly. Both functions are achieved using the same micro-LED light source and diffuser structure, eliminating the need for separate masking techniques and reflector modifications. The control system integrates both functions to operate from a single light source, reducing manufacturing complexity while maintaining reliable indication for both blind spot detection and turn signal purposes.
2Shape
If masking layers are used to shape the light for display icons, then the icon shape is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the masking layer from the system entirely. Instead of using masking layers to shape the light, the invention uses a diffuser with a specific optical property that naturally shapes the light into the desired icon form. The diffuser is positioned at a specific distance from the micro-LED array, allowing the light to self-form into the display icon shape without any masking material, thereby simplifying manufacturing.
Solution Approach 2:
The patent introduces a diffuser as an intermediary element between the micro-LED light source and the mirror element. This diffuser mediates the light transformation process by shaping the light into the desired icon form through its optical properties and positioning, replacing the need for masking layers while maintaining the ability to create specific display icon shapes.
3Illumination intensity
If traditional lighting assemblies are used, then illumination is provided, but image distortion occurs and light intensity is reduced
Solution Approach 1:
The patent replaces traditional mechanical lighting assemblies with a micro-LED based lighting subassembly. The micro-LEDs provide more precise light control and higher intensity while the integrated diffuser design minimizes image distortion. The substitution of the traditional lighting mechanism with this newer technology enables both increased light intensity and reduced image distortion simultaneously.
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 enables efficient and cost-effective production of vehicle mirrors with integrated blind spot detection and turn signal indicators, enhancing driver assistance features without the need for complex masking techniques, while maintaining minimal image distortion and increased light intensity.
Implementation Method 1
The light source includes a plurality of micro light-emitting diodes arranged in a light shape representing a display icon
Implementation Method 2
A diffuser is disposed between the light source and the mirror element
Implementation Method 3
the mirror element is an electrochromic mirror element having a variable reflectance
Implementation Method 4
a heating element disposed in the PCB substrate for heating the mirror element
Data Source
AI summary
A rearview mirror assembly includes a mirror element including a first substrate having a first surface and a second surface. A reflector is disposed adjacent to one of the first and second surfaces. The rearview mirror assembly further includes a lighting subassembly includes a light source and a diffuser. The light source is operable to project light through the mirror element. The diffuser is disposed between the light source and the mirror element. The light source comprises a plurality of micro light-emitting diodes arranged in a light shape representing a display icon such that the display icon is projected through the mirror element without any influence on the shape caused by any other component of the mirror element.