Printable LED Rearview Mirror Assembly
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Solution Overview
Problem
Existing rearview mirror assemblies lack efficient and cost-effective solutions for integrating light-emitting diodes (LEDs) that provide directional, high-intensity lighting with flexible and thin profiles, suitable for automotive applications, while also enabling new lighting and display capabilities.
Innovation Solution
The use of printable light-emitting diodes (LEDs) with screen printable transparent conductive coatings and inorganic semiconductor inks, allowing for the creation of thin, flexible, and low-profile lighting units that can be integrated into various automotive components, including mirror assemblies and door handles, using additive manufacturing and 3D printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional LED integration methods are used in rearview mirror assemblies, then lighting functionality is achieved, but the profile thickness and flexibility are insufficient for modern automotive design requirements
Solution Approach 1:
The LED lighting unit is segmented into multiple functional layers including a substrate, printable LED elements, transparent conductive coatings, and encapsulant materials. This segmentation allows each layer to be optimized independently for thinness while maintaining overall functionality
Solution Approach 2:
The patent employs thin film structures throughout the LED unit, including transparent conductive coatings deposited as thin films and encapsulant materials that form protective yet flexible shells. This enables the lighting unit to achieve a thin profile while maintaining structural integrity and flexibility for integration into mirror assemblies
2Illumination intensity
If high-intensity directional lighting is implemented, then illumination performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent implements local quality by positioning printable LED elements at specific locations and orientations on the substrate to achieve directional lighting. The transparent conductive coatings are applied selectively to specific areas to conduct electricity to the LED elements while maintaining optical transparency in other regions, thereby achieving high-intensity directional lighting without requiring complex overall structure
Solution Approach 2:
The patent replaces traditional mechanical LED mounting and wiring structures with printable technologies. Conductive inks and paints are printed directly onto the substrate to create electrical connections, eliminating the need for separate mechanical connectors and wires. This substitution reduces structural complexity while maintaining the ability to deliver high-intensity directional light
3Ease of manufacture
If printable LED technology is used, then manufacturing cost and flexibility are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs parameter changes in the form of adjustable printing parameters such as ink concentration, deposition speed, and curing conditions to optimize the manufacturing process. By controlling these parameters, the system achieves the required manufacturing precision for conductive pattern placement and LED element positioning while maintaining the cost-effectiveness and flexibility of printable manufacturing methods
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 solution provides a cost-effective, flexible, and high-intensity lighting system that can be used in various automotive applications, offering improved directionality and spectral control, with the ability to create moving images and animations, while being compatible with existing electrochromic mirror technologies.
Implementation Method 1
The display element comprises a printable light emitting diode
Implementation Method 2
screen printable transparent conductive coatings
Data Source
AI summary
A rearview mirror assembly for a vehicle includes a mirror reflective element having at least one glass substrate and a mirror reflector established at a surface of said at least one glass substrate. The mirror assembly includes a display element disposed at the rear of the mirror reflective element and operable to emit light that is viewable through the mirror reflective element. The display element includes a printable light emitting diode. The mirror assembly may include at least one of (a) a printable electrically conductive layer at a surface of the at least one glass substrate, (b) a printable heater pad established at a rear surface of the at least one glass substrate, (c) a printable touch sensor and (d) a moldable light emitting diode element.