Vehicle Mirror Mount Assembly with Conical Attachment
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Solution Overview
Problem
Existing mirror stay and mount assemblies for vehicles lack a secure and adjustable mechanism to attach rearview mirrors to vehicle headers or windshields, particularly in preventing rearward disengagement and ensuring a stable electrical connection.
Innovation Solution
A mirror stay or mount assembly with a mounting member formed by injection molding a thermoplastic polymeric resin, featuring a pivot element and an attachment member with a knurled or conical connection portion to provide a fixed and secure attachment, and a hollow interior for housing electrical wires, allowing for adjustable and secure attachment to vehicle headers or windshields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a frictional adjustment mechanism is used at the pivotal connection, then the mirror can be adjusted to different positions, but the mirror may become loose or disengage due to insufficient securing
Solution Approach 1:
The attachment member is nested within the mounting member through insert molding, where the attachment member is inserted into a cavity of the mounting member and permanently bonded. This nesting creates a secure mechanical interlock that prevents disengagement while maintaining the pivotal adjustment capability through the ball-socket joint design.
Solution Approach 2:
The mounting assembly uses composite construction combining a thermoplastic polymeric resin for the mounting member with a metal attachment member. This composite approach provides both the adjustability of the metal pivot mechanism and the securing strength of the molded polymer structure, resolving the contradiction between ease of operation and reliability.
2Adaptability or versatility
If the attachment member is made detachable for adjustment, then the mirror can be repositioned, but rearward disengagement may occur
Solution Approach 1:
The insert molding process performs the attachment action in advance by permanently bonding the attachment member to the mounting member during manufacturing. This preliminary securing action ensures that the connection is established before use, preventing rearward disengagement while allowing pivotal repositioning through the ball-socket joint.
3Ease of manufacture
If a simple mounting structure is used, then manufacturing is easier, but electrical wires cannot be properly housed
Solution Approach 1:
The mounting member is designed with multi-functionality, serving both as the structural mounting component and as the housing for electrical wires. The cavity structure of the mounting member simultaneously provides mechanical attachment and electrical wire routing, eliminating the need for separate housing components while maintaining ease of manufacture through integral molding.
4Reliability
If a knurled surface is used on the connection portion, then the overmolded connection is more secure, but the manufacturing complexity increases
Solution Approach 1:
The knurled surface feature is merged directly into the attachment member during its formation process, rather than being added as a separate component or post-processing step. This integration combines the attachment member and its securing features into a single manufactured part, increasing connection strength through the knurled surface while avoiding additional manufacturing 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 provides a secure and adjustable attachment mechanism that prevents rearward disengagement of the mirror and ensures a stable electrical connection, enhancing the durability and functionality of the mirror stay or mount assembly.
Implementation Method 1
The mounting member may be formed by injection molding a thermoplastic polymeric molding resin
Implementation Method 2
the connection portion of the attachment member may include a knurled or otherwise unsmooth surface that is overmolded by the lower portion of the mounting member to provide a substantially fixed connection therebetween
Implementation Method 3
the connection portion of the attachment member may include a conical shape or other shape that is angled to be overmolded by the lower end of the mounting member to limit or prevent rearward disengagement of the attachment member from the mounting member
Data Source
AI summary
A vehicular interior rearview mirror assembly includes a mirror head, a mounting member configured to mount at an interior portion of a vehicle, and an attachment member having a connecting portion, a flange, a neck and a pivot element. The attachment member includes a conical portion that tapers from the flange portion toward the neck of the attachment member. The pivot element is disposed at an opposite end of the neck from the conical portion. With the attachment member disposed at a lower portion of the mounting member, and with the connecting portion received in and secured at a receiving portion of the mounting member, the flange abuts an end of the lower portion of the mounting member and an outer surface of the conical portion corresponds with an outer surface of the lower portion of the mounting member. The mirror head is adjustably attached at the pivot element.