Rearview Mirror Mounting Assembly with Overmolded Electrical Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing interior rearview mirror mounting assemblies require manual pressing of ball members into sockets, which is labor-intensive and prone to errors, and do not easily accommodate electrical connections for modern features like compass systems or display integration.
Innovation Solution
A mounting assembly with a polymeric mounting arm and overmolded channel mount or toggle portion, allowing for unitary molding of the assembly and inclusion of electrical conductors, eliminating the need for manual ball member insertion and enabling integration of electrical components like compass sensors and displays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual pressing of ball members into sockets is used, then the mounting assembly can be assembled, but the process is labor-intensive and prone to errors
Solution Approach 1:
The patent combines the ball member insertion process with the socket molding process into a single integrated operation. The ball members are inserted into the mold cavities before the socket material is injected, allowing the socket to be molded directly over the ball members in one continuous process. This eliminates the separate manual pressing operation and integrates two previously distinct steps into one automated molding cycle, thereby improving ease of manufacture and productivity simultaneously.
2Adaptability or versatility
If traditional mounting assemblies are used, then the basic mounting function is provided, but electrical connections for modern features cannot be easily accommodated
Solution Approach 1:
The socket component is designed to perform multiple functions simultaneously: it provides the mechanical mounting function by securing the ball member through friction fit, and it also serves as a conduit for electrical connections. The socket's internal cavity and structural design allow electrical wires to pass through or be routed within it, enabling the assembly to accommodate both mechanical and electrical requirements in a single integrated component rather than requiring separate mounting and wiring assemblies.
Solution Approach 2:
The patent merges the mechanical mounting structure (socket and ball member) with the electrical connection pathway into a single integrated assembly. The socket is molded to include features that guide and protect electrical conductors, combining what were traditionally separate mechanical and electrical subsystems into one unified component that handles both mounting and wiring functions.
3Strength
If ball members are pressed into sockets manually, then the components can be joined, but the process is time-consuming
Solution Approach 1:
The ball members are inserted into the mold cavities and positioned in advance before the socket material is injected. This preliminary placement ensures that the ball members are already in their correct positions and orientations when the molding process begins, eliminating the need for time-consuming manual alignment and insertion operations. The friction-fit connection is established automatically as the socket material cures around the pre-positioned ball members, maintaining mounting integrity while dramatically reducing assembly time.
Data Source
AI summary
A rear vision system for a vehicle includes a rear backup video camera and a display device. A control activates display of captured video images by the display device when a transmission of the vehicle is shifted into reverse gear and deactivates display of the video images upon shifting of the vehicle transmission out of reverse gear once a threshold deactivation condition is met. The threshold deactivation condition is at least one of (a) forward travel of the vehicle exceeding a threshold speed of forward movement after the vehicle transmission has been shifted out of reverse gear, (b) forward travel of the vehicle exceeding a threshold distance of forward movement after the vehicle transmission has been shifted out of reverse gear and (c) a threshold period of time elapsing after the vehicle transmission has been shifted out of reverse gear, the threshold period of time constituting a linger time.