Low Profile Optical Lighting Assembly for Vehicle Mirror
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Solution Overview
Problem
Existing optical lighting assemblies for outside vehicle mirrors are limited by their thickness, making it difficult to fit within the constrained space of the mirror housing while providing adequate illumination for blind spot detection and other driver assist functions.
Innovation Solution
The implementation of a low-profile optical lighting module that uses a thru-board or edge-lit configuration with LEDs mounted on the rear surface of a PCB, combined with a TIR optic or optical diffuser, to direct light through a heating element and onto the mirror glass, reducing overall thickness and using a cover to protect the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional optical lighting assemblies are used to illuminate indicia in outside vehicle mirrors, then adequate illumination intensity is achieved, but the assembly thickness exceeds the available space in the mirror housing
Solution Approach 1:
The patent transitions from conventional front-mounted LED configurations to edge-lit and thru-board mounting configurations. This dimensional repositioning allows the optical components to be arranged in different spatial orientations, reducing the thickness dimension while maintaining illumination effectiveness through the mirror glass.
Solution Approach 2:
The patent integrates multiple functional layers within a compact thickness of less than 9mm. The LED array, PCB, optical diffuser, and heating element are nested in a stacked configuration where each layer serves multiple functions, allowing adequate illumination intensity to be achieved without exceeding the mirror housing space constraints.
2Length of moving object
If the optical lighting assembly thickness is reduced to fit within mirror housing constraints, then space availability is improved, but light intensity and illumination effectiveness may be compromised
Solution Approach 1:
The patent modifies key parameters including LED density (increasing from conventional arrangements to arrays with multiple LEDs per indicator region), optical diffuser material properties, and mounting configuration. These parameter changes enable the assembly to maintain adequate light intensity despite the reduced thickness constraint of less than 9mm.
Solution Approach 2:
The patent employs composite material structures including the combination of LED arrays with optical diffusers made from specific materials that maximize light transmission and distribution. The integration of heating elements with the optical assembly creates a composite structure that serves both illumination and anti-fogging functions within the limited thickness.
3Length of moving object
If a compact low-profile design is implemented, then device size is reduced, but protection of internal components from debris may be insufficient
Solution Approach 1:
The patent incorporates a thin transparent cover or lense that protects the internal LED array and PCB from debris while maintaining the low-profile design. This thin film structure provides necessary protection without significantly increasing the assembly thickness, allowing the device to remain under 9mm while safeguarding sensitive components.
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 achieves a thinner profile of less than 9 mm, allowing for effective illumination of indicia in the mirror glass while preventing debris entry and maintaining light intensity, thus enhancing driver visibility in both daylight and darkness.
Implementation Method 1
The optic device 205 comprises a first lens surface having a total internal reflector (TIR) portion surrounding a refractive portion
Implementation Method 2
combined with a TIR optic or optical diffuser, to direct light through a heating element and onto the mirror glass
Data Source
AI summary
An optical lighting assembly for use with a vehicular outside rearview mirror includes a printed circuit board (PCB) having a light source such as a light emitting diode (LED) mounted thereon. An optical device such as a light pipe is positioned adjacent to the LED for propagating light away from the LED. A mirror element includes at least one indicia where light escaping from the light pipe is used to illuminate the indicia.