Pour Molded Diffuser with Refractive Particles for Lighted Mirrors
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Solution Overview
Problem
The manufacturing process of lighted mirrors with diffusers is burdensome and costly, involving cutting and processing of materials like plastic or acrylic, followed by attachment to other components.
Innovation Solution
The use of pour molding to create a diffuser from a resinous material, which includes refractive particles, and is integrated with a light source and frame, simplifying the manufacturing process and eliminating the need for complex cutting and etching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cutting and etching processes are used to manufacture diffusers, then light scattering functionality is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the manufacturing parameters from mechanical cutting and chemical etching to a molding process. The diffuser is created by molding a translucent material directly into the desired shape with integrated light scattering features, eliminating complex post-processing steps while maintaining optical functionality.
Solution Approach 2:
The patent uses a composite material approach by incorporating light scattering particles or creating a translucent matrix with specific internal structures during the molding process. This allows the diffuser to achieve light scattering functionality through material composition rather than surface processing.
2Device complexity
If multiple separate components are used for diffuser and frame, then assembly flexibility is maintained, but device complexity increases
Solution Approach 1:
The patent merges the diffuser and frame into a single integrated component. The molding process creates a unified structure where the diffuser is formed as an integral part of the frame assembly, reducing the number of separate parts while maintaining the necessary functional zones for light diffusion and structural support.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it provides structural support as a frame, light diffusion through the translucent material, and defines the housing structure. This multi-functionality reduces overall device complexity without sacrificing assembly flexibility.
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 method reduces manufacturing complexity and costs while providing a more uniform and brighter light through the frosted edge of the mirror, enhancing the aesthetic and functional qualities of the lighted mirror.
Implementation Method 1
The diffuser may include a plurality of refractive particles configured to refract light traveling through the diffuser
Implementation Method 2
a diffuser configured to diffuse (e.g., scatter, soften) light generated by a light source
Data Source
AI summary
A mirror assembly includes mirrored glass, at least one frosted edge disposed along a side of the mirrored glass, a diffuser disposed behind the at least one frosted edge, the diffuser including a plurality of refractive particles suspended in a substrate, and a light source configured to generate light. The plurality of reflective particles may refract light generated by the light source and the refracted light may travel through the at least one frosted edge.