Modular Mirror Assembly with Collar for Precise Wall Mounting
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Solution Overview
Problem
The installation of fixed tilt mirrors with a one-piece design is challenging due to the inability to visually locate the hanger brackets on the wall, making it difficult and time-consuming to mount them accurately.
Innovation Solution
A modular mirror assembly with a separate collar and mirror design, featuring notched cross-members and a locking mechanism, allows for precise mounting by ensuring the hanger fits into the notch and is locked in place, eliminating the need to estimate bracket locations during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece mirror design is used, then the mirror structure is simple and robust, but the installation becomes difficult and time-consuming due to inability to visually locate hanger brackets
Solution Approach 1:
The mirror assembly is divided into separate components: a collar component and a mirror component. The collar is mounted on the wall first with visible positioning features, allowing precise location of hanger brackets. The mirror is then separately attached to the collar, enabling accurate alignment without guessing bracket positions, thus reducing installation time while maintaining structural integrity.
2Device complexity
If a one-piece mirror design is used, then the mirror structure is simple, but the installation precision deteriorates as bracket locations must be estimated
Solution Approach 1:
The collar is pre-mounted on the wall at the desired location and orientation before the mirror is attached. The collar includes visible positioning features and notched cross-members that establish precise mounting locations. This preliminary positioning action ensures accurate bracket location without requiring estimation during the mirror attachment phase.
3Manufacturing precision
If a separate collar and mirror design is used, then installation precision is improved with visible bracket locations, but device complexity increases
Solution Approach 1:
The mirror assembly is segmented into a collar component and a mirror component. The collar serves as a mounting interface with visible positioning features, while the mirror attaches to the collar. This segmentation provides precise mounting capability without requiring complex integrated designs, as each component has a specific function.
Solution Approach 2:
The collar and mirror components are combined into a single mirror assembly unit. The collar includes notched cross-members that receive hangers from the mirror, and a locking mechanism secures the mirror to the collar. This merging provides precise mounting while maintaining relative simplicity through functional integration of the components.
4Loss of time
If a separate collar and mirror design is used, then installation time is reduced with accurate bracket positioning, but ease of manufacture deteriorates
Solution Approach 1:
The mirror assembly is segmented into separately manufacturable collar and mirror components. The collar can be manufactured with notched cross-members and locking mechanisms, while the mirror is manufactured with hangers. These components are then assembled by attaching the mirror to the collar, providing accurate positioning without requiring complex integrated manufacturing processes.
Data Source
AI summary
A mirror assembly including a collar including two side walls spaced apart from each other and a transverse member coupled to the two side walls, and a mirror releasably coupled to the transverse member. A method a method of installing a mirror includes mounting a collar on the wall, and mounting a mirror on the collar after it is mounted on the wall. A method of forming a collar from a strip of material.