Composite Rearview Mirror Mount Base for Stress and Rattle Control
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Solution Overview
Problem
Existing rearview mirror mount bases made of metal materials suffer from rattle noise, rust, corrosion, high manufacturing costs, and weight issues, while failing to effectively distribute stress when fastened, potentially damaging the windshield.
Innovation Solution
A mount base design incorporating a base body made of a resin material with an embedded metallic insert, providing increased stiffness and weight reduction, and featuring stress-absorbing members and air layers to distribute axial forces uniformly, thus minimizing deformation and preventing damage to the windshield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal material (sintered stainless steel alloy) is used for the mount base, then strength and stiffness are improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent applies composite materials by combining a resin base body with a metal insert. The base body is made of resin material, and a metal insert (stainless steel or aluminum alloy) is embedded within it. This composite structure provides the strength and stiffness of metal where needed (at the screw fastening point) while maintaining the weight reduction benefits of resin for the overall mount base structure.
2Strength
If a metal material (sintered stainless steel alloy) is used for the mount base, then strength and stiffness are improved, but rattle noise and rust/corrosion occur
Solution Approach 1:
The composite structure of resin base body with metal insert eliminates rattle noise by providing vibration damping through the resin material while preventing rust and corrosion by limiting metal exposure only to the embedded insert portion, which is protected by the surrounding resin.
Solution Approach 2:
The patent uses aluminum alloy as an alternative metal insert material that is more corrosion-resistant and easier to manufacture than sintered stainless steel, reducing both cost and susceptibility to rust while maintaining adequate strength for the application.
3Strength
If a metal material (sintered stainless steel alloy) is used for the mount base, then strength is improved, but manufacturing cost increases
Solution Approach 1:
The composite structure allows the use of lower-cost resin material for the base body, reducing overall material cost compared to using sintered stainless steel throughout. The metal insert is used only where strength is critical, optimizing the balance between cost and performance.
Solution Approach 2:
The patent employs aluminum alloy inserts or other cost-effective metal materials instead of expensive sintered stainless steel, significantly reducing manufacturing cost while maintaining adequate strength through the composite structure design.
4Reliability
If a screw is fastened to the mount base, then fixation is achieved, but stress concentration occurs and windshield damage risk increases
Solution Approach 1:
The patent applies local quality by concentrating the metal insert material specifically at the screw fastening location where stress concentration occurs. This localized reinforcement provides stress distribution capability exactly where needed, protecting the windshield from damage while maintaining fixation reliability.
Solution Approach 2:
The composite structure of resin with embedded metal insert creates a transition zone that distributes screw fastening stress. The metal insert handles the concentrated load at the screw point, while the surrounding resin material distributes the stress over a larger area, preventing stress concentration that could damage the windshield.
Data Source
AI summary
A mount base for a rearview mirror includes: a base body including a first material; and an insert embedded in the base body and including a second material. The base body has a first surface and a second surface opposing the first surface, the insert has a first surface and a second surface opposing the first surface, the first material is softer than the second material, and the second material has higher stiffness than the first material.