Plastic Mirror Base with Integrated Steel Bolts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mirror bases, particularly those made of metallic components, are heavy, complex to manufacture, and contribute to increased vehicle weight and CO2 emissions, while plastic alternatives lack sufficient stiffness and vibration resistance.
Innovation Solution
A mirror base partially extruded from plastic with integrated fastening bolts, which provide precision and torsional stiffness, combined with optional metallic components like die-cast axles and threaded bodies for enhanced stability and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic mirror bases are used, then strength and stability are improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent employs a composite construction combining plastic and metal components. The mirror base consists of a plastic carrier plate integrated with metal reinforcement elements and mounting brackets, creating a hybrid structure that leverages the weight advantages of plastic while incorporating metal where strength and stiffness are critical for mounting and structural support.
Solution Approach 2:
The mirror base is divided into functionally distinct segments: a plastic carrier plate for the mirror assembly, separate metal mounting brackets for vehicle attachment, and integrated reinforcement elements. This segmentation allows each component to be optimized for its specific function while reducing overall weight compared to a fully metallic construction.
2Strength
If metallic mirror bases are used, then strength and stability are improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into integrated components. The mounting brackets are directly formed as part of the carrier plate structure, and reinforcement elements are integrated into the plastic body during molding. This integration reduces the number of separate parts and assembly steps compared to traditional multi-component metallic constructions.
Solution Approach 2:
The composite construction allows the use of plastic for non-critical structural areas while incorporating metal only where absolutely necessary for mounting strength, thereby reducing overall complexity compared to fully metallic designs that require extensive machining and assembly.
3Weight of moving object
If plastic mirror bases are used, then weight is reduced, but torsional stiffness and vibration resistance deteriorate
Solution Approach 1:
The patent applies local reinforcement where needed rather than uniformly strengthening the entire structure. Metal reinforcement elements and mounting brackets are strategically positioned at critical locations where torsional stiffness and vibration resistance are most required, while other areas maintain the weight advantages of plastic construction.
Solution Approach 2:
The hybrid plastic-metal construction provides torsional stiffness and vibration resistance through the strategic integration of metal reinforcement elements within the plastic carrier plate structure, achieving the required mechanical performance without the weight penalty of a fully metallic base.
4Weight of moving object
If plastic mirror bases are used, then weight is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The mounting brackets and reinforcement elements are pre-formed and integrated into the carrier plate during the molding process, ensuring precise positioning and geometry before final assembly. This preliminary formation of critical features during manufacturing improves overall precision while maintaining weight advantages.
Data Source
AI summary
A mirror base is proposed that is extruded at least partially out of plastic and which retains its rigidity via long steel bolts, which at the same time produce the fastening to the vehicle.