Rearview Mirror Bezel-Glass Assembly for Uniform Gap Control
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Solution Overview
Problem
Conventional rearview mirror assemblies often exhibit non-uniform gaps between the glass edge and the bezel or housing, leading to aesthetic issues and potential stress due to thermal expansion differences, which can result in damage and an unsightly appearance.
Innovation Solution
A rearview mirror assembly with a tight line-to-line fit between the electro-optic element and the bezel, utilizing a filler to minimize the gap and incorporating a reinforcement with low thermal expansion coefficients to manage thermal stress, and integrating the bezel with the substrates for a seamless appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cutting techniques (scribe and break, abrasive wheel, water jet) are used to cut glass, then manufacturing is easier and faster, but non-uniform gaps appear between the glass edge and the bezel
Solution Approach 1:
The patent applies laser cutting technology which fundamentally changes the cutting parameter from mechanical (scribe/break, abrasive wheel) or thermal (water jet) to focused high-energy laser ablation. This parameter change enables precise control of the cut depth and edge quality, achieving uniform gaps between glass and bezel while maintaining high manufacturing efficiency. The laser can be precisely controlled to cut only through the glass substrate without affecting the bezel, ensuring consistent gap dimensions.
2Reliability
If large gaps are left between the glass and bezel to accommodate thermal expansion, then the glass is protected from stress damage, but the aesthetic appearance deteriorates with visible non-uniform gaps
Solution Approach 1:
The patent implements local quality by applying different gap requirements to different regions. The laser cutting technique enables a tight fit (minimal gap) at the interface between glass and bezel for aesthetic purposes, while simultaneously providing sufficient clearance in other areas to accommodate thermal expansion. The precision laser cut creates a controlled interface that protects the glass from stress concentration at the edge while maintaining visual appeal.
Solution Approach 2:
The patent employs composite construction by integrating the glass substrate with the bezel structure through precise laser cutting. The resulting assembly combines the aesthetic tight fit of minimal gaps with the functional requirements of thermal expansion accommodation. The laser-cut edge creates a clean interface that allows the glass and bezel materials to work together as a composite structure, achieving both visual seamless appearance and stress distribution.
3Shape
If the bezel is tightly fitted to the glass edge for a seamless appearance, then aesthetic appearance improves, but thermal stress concentration increases risking glass damage
Solution Approach 1:
The patent changes the interface parameter from a conventional mechanical joint with visible gaps to a laser-cut precision joint. The laser cutting process creates a clean, uniform edge on the glass that enables a tight fit with the bezel, achieving seamless appearance. Simultaneously, the precise control of cut depth and edge quality reduces stress concentration by eliminating irregularities that would act as stress points during thermal cycling.
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 achieves a uniform and aesthetically pleasing appearance by minimizing visible gaps and reducing thermal stress, ensuring the structural integrity and longevity of the mirror assembly while maintaining a seamless transition between components.
Implementation Method 1
the edge of the glass substrate has been cut with a laser
Implementation Method 2
to prevent the accumulation of stress in the glass as the mirror product undergoes a change in thermal conditions such as a change in size due to thermal expansion or contraction
Data Source
Figure 1A~1B
Figure 1C~2B
Figure 2C~3B
AI summary
A rearview mirror assembly includes a housing, a bezel and an electro-optic mirror element. The electro-optic mirror element includes a first substantially transparent substrate having an edge extending around at least a portion of a perimeter of the first substantially transparent substrate and a second substrate having a second edge extending around at least a portion of a perimeter of the second substrate and a fourth surface. The first substantially transparent substrate and the second substrate define a cavity therebetween. An electro-optic material is disposed within the cavity. The edge of the first substantially transparent substrate and the second edge of the second substrate are coupled to at least one of the bezel and the housing.