Mirror Head Assembly with Frangible Toggle Mechanism
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Solution Overview
Problem
Existing interior rearview mirror assemblies for vehicles require complex mounting configurations with multiple fasteners and components, making assembly and adjustment cumbersome, and lack efficient mechanisms for toggling between daytime and nighttime reflectivity positions.
Innovation Solution
The use of a metallic spring clip for attaching the mirror assembly to a windshield without fasteners, combined with a toggle mechanism molded as a single piece that separates into two parts during assembly, allowing for snap attachment and adjustment of the mirror head without additional components, and a prismatic reflective element that can be easily toggled between viewing angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting configurations with multiple fasteners are used, then the mirror assembly can be securely attached to the windshield, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The spring clip integrates multiple functions (mounting, securing, and adjustment) into a single component that combines a clip body with integrated arms and friction adjustment capability, eliminating the need for separate fasteners and mounting hardware
Solution Approach 2:
The spring clip uses its own elastic deformation and friction characteristics to secure the mirror head to the button, requiring no external fasteners or additional components, and allows self-adjustment through friction-based engagement
2Adaptability or versatility
If multiple separate components are used for the toggle mechanism, then each component can be optimized for its specific function, but the number of parts increases and assembly becomes more difficult
Solution Approach 1:
The toggle mechanism body and lever are molded as a single integrated piece with a frangible web connecting the pivotable lever to the body, reducing the number of parts while maintaining the ability to pivot and toggle between positions
Solution Approach 2:
The integrated toggle mechanism includes a frangible web that allows the lever to be pivotally attached to the body, creating a segmented functional relationship within a single molded component that enables toggling between daytime and nighttime positions
3Reliability
If set screws and additional fasteners are used for adjustment, then the mirror head can be securely adjusted to desired positions, but the adjustment process becomes cumbersome and requires additional tools
Solution Approach 1:
The spring clip provides friction-based engagement with the mirror head that allows for tool-free adjustment by simply applying pressure to reposition the mirror, while maintaining secure holding at the adjusted position through friction
Solution Approach 2:
The spring clip's elastic arms provide a dynamic friction-based connection that allows the mirror head to be easily repositioned by overcoming the friction force, while maintaining secure attachment when positioned
4Device complexity
If a single-piece toggle mechanism is molded and then separated, then assembly is simplified and fewer components are needed, but the frangible web must be broken during assembly
Solution Approach 1:
The toggle mechanism is pre-formed as a single molded piece with a frangible web, allowing the lever to be pivotally attached to the mirror casing first, and then the web is broken to complete the assembly in a straightforward sequence
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
This solution simplifies the assembly process by eliminating the need for set screws and reducing the number of parts, while enabling easy adjustment of the mirror's viewing angle, enhancing ease of use and reducing manufacturing complexity.
Implementation Method 1
a metallic spring clip for attaching the mirror assembly at a mirror mounting button
Implementation Method 2
The spring clip may include a friction adjustment feature or structure
Implementation Method 3
the thin frangible web is broken to separate the toggle lever from the body portion
Implementation Method 4
a prismatic reflective element and a mirror casing with a toggle mechanism or assembly that adjusts the viewing angle of the prismatic reflective element
Implementation Method 5
prismatic reflective element that may be manually toggled between daytime and nighttime reflectivity positions
Data Source
AI summary
A method of assembling a mirror head for an interior rearview mirror assembly for a vehicle includes providing a mirror casing, a prismatic reflective element at the mirror casing, and a toggle mechanism. A pivot mount of the toggle mechanism is inserted into an upper or lower receiving portion of the mirror casing, and a body portion of the toggle mechanism is separated from a toggle lever of the toggle mechanism via breaking a frangible portion of the toggle mechanism. After breaking the frangible portion of the toggle mechanism, a second pivot mount of the toggle mechanism is inserted into the lower or upper receiving portion of the mirror casing, whereby corresponding engaging surfaces of the body portion and the toggle lever engage one another such that, when the toggle lever pivots relative to the lower receiving portion of the mirror casing, the mirror casing pivots relative to the body portion.