Rear View Mirror Lens Integration via Insert Molding
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Solution Overview
Problem
Existing rear view assemblies with light sensors often require mechanical fasteners for the light sensor lens, which can lead to accidental removal, increased material usage, and complexity in design.
Innovation Solution
An integrally formed light sensor lens is embedded within the housing of the rear view assembly, using a molding process with mold halves to create a seamless and secure attachment, eliminating the need for mechanical fasteners and enhancing aesthetic appeal by directing ambient light effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical fasteners are used to attach the light sensor lens, then the lens can be securely fixed, but the design complexity increases and material usage increases
Solution Approach 1:
The light sensor lens is integrally formed as a unified structure with the housing, eliminating the need for separate fasteners. The lens becomes an inherent part of the housing through integral formation, reducing component count and design complexity while maintaining secure attachment.
Solution Approach 2:
The housing structure serves multiple functions: it provides structural support, aesthetic appearance, and integrated lens attachment. The integral formation allows the housing to simultaneously hold and secure the lens without requiring additional fastening mechanisms.
2Reliability
If mechanical fasteners are used to attach the light sensor lens, then the lens can be securely fixed, but the material usage increases
Solution Approach 1:
The lens and housing are combined into a single integral structure, eliminating the need for separate fastener components. This reduces the total quantity of materials required while maintaining secure lens attachment through the unified design.
3Reliability
If mechanical fasteners are used to attach the light sensor lens, then the lens can be securely fixed, but the aesthetic appeal decreases
Solution Approach 1:
The integral formation of the lens with the housing creates a seamless, smooth surface without visible fasteners or joints. This unified structure enhances aesthetic appeal by eliminating visual disruptions while maintaining secure lens attachment.
4Ease of manufacture
If traditional molding process is used without light sensor lens integration, then the manufacturing is simpler, but the lens attachment requires additional steps
Solution Approach 1:
The light sensor lens is positioned and integrated into the housing during the molding process itself, before the housing is completed. This preliminary action eliminates subsequent assembly steps for lens attachment, improving overall productivity without significantly complicating the molding process.
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 provides a robust and weight-efficient rear view assembly with improved light capture capabilities, reduced material usage, and simplified manufacturing by eliminating the need for fasteners, resulting in a sleek and functional design.
Implementation Method 1
A polymeric material is injected between the first mold half and the second mold half to define at least a portion of a rear view assembly housing
Data Source
AI summary
A rear view assembly includes a housing, an electro-optic assembly disposed within the housing, and an ambient light sensor operably coupled with the electro-optic assembly. An at least partially light transmissive light sensor lens is integrally formed as part of the housing proximate the ambient light sensor. The light sensor lens is free of mechanical fasteners.