Vehicle Mirror Housing With Jointless Outer Shell Assembly
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Solution Overview
Problem
Existing mirror housings face challenges in achieving a high-quality appearance with minimal joints while maintaining cost-effectiveness, as they often require precise manufacturing and assembly to avoid joint-related issues and deformation of cast or injection-molded components.
Innovation Solution
The inner shell is designed to be elastically deformable, allowing it to be inserted into the outer shell through the mirror opening, enabling the outer shell to form the outer contour without joints, and the inner shell to form a frame contour, with optional undercut contours for positive locking and closure elements for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the mirror housing uses separate outer shell and inner shell components, then the frame contour can be optimized for the mirror, but joints are formed that compromise visual appearance and require high precision manufacturing
Solution Approach 1:
The patent combines the outer shell and inner shell into a single integrated mirror housing component. This merging eliminates the joint between separate components, achieving a jointless outer contour while maintaining both the outer contour shape and frame contour optimizations. The integrated design allows the housing to provide both protective enclosure and mirror framing functions without visible seams or joints.
2Ease of manufacture
If the outer shell and inner shell are cast or injection-molded parts, then production cost is reduced, but deformation occurs during casting or molding that compromises precision
Solution Approach 1:
The patent segments the mirror housing into multiple regions within a single integrated component: an outer contour region optimized for external appearance and a frame contour region optimized for mirror support. This segmentation allows different portions of the housing to be optimized for different functions while maintaining manufacturing efficiency through single-piece production via casting or injection molding, avoiding the precision losses associated with assembling multiple precision components.
3Strength
If the outer contour is formed by both outer shell and inner shell, then structural support is provided, but joints are unavoidable that require high precision assembly
Solution Approach 1:
The patent merges the outer shell and inner shell into one integrated housing that provides both outer contour definition and frame contour support simultaneously. This eliminates the need for precision assembly between separate components while maintaining the structural support benefits of having both outer and inner structural elements. The integrated design ensures uniform material properties and eliminates joint-related weakness points.
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 approach allows for a jointless outer contour, reduced manufacturing costs, and improved visual appeal by eliminating the need for additional fastening means and integrating closure elements with existing components like outer mirror indicators, while maintaining adjustability of the mirror assembly.
Implementation Method 1
The inner shell (7) is designed to be elastically deformable, allowing it to be inserted into the outer shell (6) through the mirror opening (8)
Data Source
AI summary
A mirror housing for an outer mirror of a vehicle, preferably a passenger car, having an outer shell for receiving a mirror assembly, and having an inner shell. The outer shell includes a mirror opening closed in a circumferential direction for arranging a mirror of the mirror assembly. The inner shell is fastened to the outer shell in the region of the mirror opening. The inner shell lines the mirror opening from the inside along the circumferential direction.