Mirror Heating Element for Multi-Surface Conformance
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Solution Overview
Problem
Conventional rearview mirror assemblies with heating elements face difficulties in conforming to multi-plane substrates, particularly those with both primary and spot mirrors, and require complex manufacturing to maintain electrical connections across multiple surfaces.
Innovation Solution
A rearview mirror assembly design featuring a heating element with a primary portion secured to the primary mirror surface and a secondary portion secured to the spot mirror surface, connected by a single conductor that winds between them, allowing for uniform heating of both surfaces through a serpentine path and a carrier with a cut out to conform to curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional heating element is used on a multi-plane mirror substrate, then the heating element can be easily manufactured, but it cannot conform to the depression in the spot mirror area
Solution Approach 1:
The heating element is divided into a first heating portion for the primary mirror surface and a second heating portion for the spot mirror surface, allowing each portion to be independently shaped to conform to its respective surface geometry while maintaining electrical connectivity through a conductor
Solution Approach 2:
The heating element transitions from a flat two-dimensional configuration to a three-dimensional conformal structure that adapts to the curved and depressed surfaces of the mirror substrate, enabling proper contact and heating functionality across non-planar surfaces
2Reliability
If multiple heating elements are used for multiple surfaces, then each surface can be heated effectively, but the electrical connection complexity increases significantly
Solution Approach 1:
Multiple heating portions that would traditionally require separate heating elements and independent electrical connections are merged into a single integrated heating element structure, sharing common electrical connections and simplifying the overall electrical system while maintaining effective heating across all mirror surfaces
Solution Approach 2:
A single heating element structure serves multiple functions by providing heating to both the primary mirror surface and the spot mirror surface through its integrated design, eliminating the need for separate heating elements and reducing electrical connection complexity
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 effective heating of both primary and spot mirror surfaces, ensuring clear visibility in all weather conditions by efficiently distributing thermal energy across the entire mirror substrate, simplifying manufacturing by maintaining electrical connections and conforming to complex surface geometries.
Implementation Method 1
a heating element fixedly secured to the second surface of the mirror for heating the mirror
Data Source
AI summary
A rearview mirror assembly for a motor vehicle includes a mirror bracket fixedly secured to the motor vehicle. A mirror case is secured to the mirror bracket. The mirror case defines a primary opening. A backing plate is operatively connected to the mirror case. A mirror is fixedly secured to the backing plate. The mirror defines a substrate having a first surface and a second surface. The second surface defines a primary mirror surface and a spot mirror surface formed within the second surface. The rearview mirror assembly also includes a heating element fixedly secured to the second surface of the mirror for heating the mirror. The heating element includes a primary portion fixedly secured to the primary surface and a secondary portion fixedly secured to the spot mirror surface.