Plastic Substrate Rear View Mirror with Integrated Illumination
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Solution Overview
Problem
Internal rear view mirrors with plastic materials face design limitations due to regulatory requirements for rounded edges and the need for additional components like bezels and lenses, which complicate manufacturing and aesthetics.
Innovation Solution
A one-piece fully transparent plastic substrate with a reflective coating, integrated into the mirror housing, serving both as the mirror and lens, eliminating the need for separate bezels and lenses, allowing for lightweight and flexible design options while meeting safety and regulatory standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic mirror case with retaining bezel is used to meet safety requirements, then passenger security is improved, but the appearance is compromised and design flexibility is reduced
Solution Approach 1:
The patent merges the retaining bezel and mirror housing into a single integrated plastic mirror case structure. The rounded peripheral edges of the housing itself serve as the retaining feature, eliminating the need for a separate bezel component while maintaining the required 2.5mm radius for passenger safety and improving aesthetic appearance.
2Reliability
If a retaining bezel is added to the mirror housing, then passenger security is improved, but manufacturing complexity and part quantity increase
Solution Approach 1:
The retaining function is merged into the mirror housing structure itself through integrated rounded peripheral edges. This single-component design eliminates the need for separate bezel parts, reducing manufacturing steps and assembly operations while maintaining the required safety features.
3Ease of operation
If glass mirror and separate lenses are used, then optical functionality is achieved, but device complexity and weight increase
Solution Approach 1:
The transparent plastic substrate serves multiple functions simultaneously: it acts as the mirror support, provides optical clarity for illumination transmission, and forms the mirror housing structure. This multi-functional design eliminates the need for separate glass mirrors and lenses, reducing component count while maintaining optical functionality.
4Reliability
If traditional mirror components are used, then regulatory requirements are met, but weight increases limiting additional functionalities
Solution Approach 1:
The patent changes the material parameter from traditional glass and metal components to transparent plastic substrate and integrated housing. This material substitution significantly reduces weight while maintaining the required 2.5mm rounded edge radius for regulatory compliance and enabling additional functionalities like GPS receivers and wireless connections.
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
The solution results in a lightweight, bezel-free internal rear view mirror design that supports additional functionalities like GPS and wireless connections without weight increase, offering improved flexibility and optical clarity similar to glass, while simplifying manufacturing and enhancing passenger safety and aesthetics.
Implementation Method 1
The transparent plastic substrate is formed in one piece and coated with a reflective layer at least partly
Data Source
AI summary
The invention is related to a rear view mirror formed by a plastic glass structure and mirror housing. The plastic glass allows smooth edges and a bezel free appearance of the mirror. The plastic glass allows in addition to shine through the mirror body to create different types of illumination in the passenger's cabin.