Vehicle Mirror Socket Decoupling for Vibration and Torque
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Solution Overview
Problem
Existing interior rearview mirror assemblies face challenges in providing sufficient support and torque while using lighter and less costly materials, and they often compromise on vibration performance due to the load path through the mirror casing.
Innovation Solution
A separate socket element is introduced, attached to the backplate instead of the mirror casing, which allows for the use of different materials for the backplate and socket element, enhancing torque and vibration performance by decoupling the load path and using materials like ABS and polypropylene for the socket element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the socket portion is attached to the mirror housing, then the structure is simpler, but the vibration performance deteriorates due to load path through the mirror casing
Solution Approach 1:
The mounting structure is segmented into separate components: the socket portion is detached from the mirror housing and instead attached to the backplate, creating distinct functional zones that separate vibration loads from the mirror casing structure
Solution Approach 2:
The backplate serves as an intermediary element between the socket portion and the mirror housing, intercepting and managing load paths to prevent vibrations from traveling through the mirror casing
2Weight of moving object
If lighter and less costly materials are used for the mirror assembly, then the weight and cost are reduced, but the torque and support properties deteriorate
Solution Approach 1:
Different material properties are applied to different components: the backplate uses lighter materials while the socket portion uses materials optimized for torque and support properties, allowing each component to be locally optimized for its specific function
Solution Approach 2:
The mounting system combines different materials in the socket portion and backplate assembly, selecting materials with complementary properties to achieve both weight reduction and adequate torque support
3Strength
If a separate socket element attached to the backplate is used, then the torque and vibration performance are improved, but the device complexity increases
Solution Approach 1:
The socket portion is segmented as a separate attachable component rather than being integrated into the housing, allowing it to be optimized for torque properties while maintaining a relatively simple overall structure through modular assembly
4Ease of manufacture
If the socket portion is integrated into the mirror housing, then the manufacturing process is simpler, but the load path causes vibration issues
Solution Approach 1:
The manufacturing process is segmented into separate steps for the socket portion and mirror housing, allowing each to be manufactured and optimized independently before final assembly, thereby reducing vibrations while maintaining manufacturing efficiency
Data Source
AI summary
A process for providing an interior rearview mirror assembly for a vehicle includes providing a mirror reflective element and forming a mirror backplate and a mounting base, with the mounting base formed separate from the mirror backplate. The mounting base is configured for attachment at an interior portion of a vehicle and includes a ball member. A socket element is formed separate from the mirror backplate and separate from the mounting base, and the socket element includes a socket member. The ball member of the mounting base is inserted into the socket member of the socket element to form a ball and socket joint whereby the mounting base pivotally attaches to the socket element. With the mirror backplate attached at the mirror reflective element, the socket element, with the mounting base pivotally attached thereto, is attached to the mirror backplate.