Optic Assembly for Mirror Using Single LED and Reflector

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Solution Overview

Problem

Existing optic assemblies for rearview mirrors are inefficient in terms of size, cost, and energy consumption, as they often require multiple light sources and emit excessive heat, despite attempts to optimize lighted auxiliary features like turn signals and blind spot detection displays.

Innovation Solution

The optic assembly incorporates a reflector with refocusing and converging facets, a mask assembly, and a single light source, such as an LED, to efficiently redirect light rays through apertures, reducing the number of LEDs needed and minimizing assembly size and heat generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If multiple light sources (LEDs) are used to provide lighted auxiliary features, then the illumination intensity and visibility are improved, but the energy consumption, heat generation, and device complexity increase

Engineering Contradiction:

Improvelight output intensityVSAvoidpower consumption

Core Design Contradiction:

Illumination intensityVSUse of energy by moving object

Solution Approach 1:

The patent combines multiple light sources into a single LED by using optical elements (lens and deviator) to split and redirect light through multiple apertures. This merging approach maintains the illumination effect of multiple LEDs while reducing power consumption to that of a single light source.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent segments the light path from a single LED into multiple beams using a lens and deviator elements. The lens divides the light from one source into multiple rays, and the deviator further redirects these rays through different apertures, creating the effect of multiple light sources without using multiple LEDs.

Inventive Principle:

Principle #1Segmentation

2Illumination intensity

If multiple light sources (LEDs) are used to provide lighted auxiliary features, then the illumination intensity is improved, but the heat generation increases

Engineering Contradiction:

Improvelight output intensityVSAvoidheat emission

Core Design Contradiction:

Illumination intensityVSTemperature

Solution Approach 1:

The patent merges the function of multiple heat-generating LEDs into a single LED, thereby maintaining the required illumination intensity while significantly reducing heat generation. The optical elements ensure that one LED can produce light output equivalent to multiple LEDs without the corresponding thermal burden.

Inventive Principle:

Principle #5Merging (Combining)

3Illumination intensity

If multiple light sources (LEDs) are used to provide lighted auxiliary features, then the illumination coverage is improved, but the device complexity and assembly size increase

Engineering Contradiction:

Improvelight output distributionVSAvoidassembly complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent merges multiple LED components into a single integrated assembly consisting of one LED, a lens, and a deviator. This reduces device complexity and assembly size while maintaining the illumination coverage and distribution that would otherwise require multiple separate LED units.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single LED assembly with lens and deviator performs multiple functions: it provides illumination through multiple apertures, directs light at specific angles, and replaces what would traditionally require multiple separate light sources. This multi-functionality reduces overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Illumination intensity

If multiple light sources (LEDs) are used to provide lighted auxiliary features, then the illumination intensity is improved, but the cost increases

Engineering Contradiction:

Improvelight output intensityVSAvoidmanufacturing cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent combines the functionality of multiple expensive LED components into a single cost-effective assembly using one LED with optical elements. This merging strategy reduces material costs, assembly costs, and manufacturing complexity while maintaining the required illumination intensity.

Inventive Principle:

Principle #5Merging (Combining)

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 design allows for the use of as few as one LED for features that previously required 4 to 9 LEDs, significantly reducing power consumption and heat emission while minimizing the optic assembly's size, thereby enhancing efficiency and cost-effectiveness.

Implementation Method 1

Light rays from a light source are substantially refocused and a portion of those light rays are substantially converged by facets on a reflector so that the light rays are emitted through one or more apertures in a mask assembly

Methodology Applied

Scientific EffectRefocusing: Reflection

Implementation Method 2

a portion of those light rays are substantially converged by facets on a reflector

Methodology Applied

Scientific EffectConverging: Reflection

Data Source

PatentUS8708536B1Optic assembly for mirror

Publication Date: 2014.04.29 MUTH COMPANY

AI summary

An optic assembly has a reflector with a reflective surface, one or more light sources, and mask assembly with one or more apertures. Light rays from a light source are refocused and substantially converged before being emitted through one or more apertures in the mask assembly.