Printed Appliqué Rearview Mirror Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rearview mirror assemblies with electro-optic materials face challenges in achieving a uniform visual appearance and adequate bond strength, particularly when using printed appliqués, which can be insufficient to support the mirror element under varying conditions such as temperature changes and humidity.
Innovation Solution
A rearview mirror assembly design that incorporates a printed appliqué with strategically placed openings filled with adhesive, ensuring a visual match between the appliqué and adhesive, and providing sufficient bond strength to support the mirror element, while also obscuring electrical contacts and other components to maintain a uniform appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a printed appliqué is used on the rear substrate, then the visual appearance is improved and electrical contacts are obscured, but the bond strength is insufficient to support the mirror element
Solution Approach 1:
The rear substrate surface is divided into two functional regions: a printed appliqué region for aesthetic purposes and electrical contact obscuration, and an adhesive region for structural bonding. This segmentation allows each region to optimize its specific function without compromising the other.
Solution Approach 2:
Different regions of the rear substrate are assigned different material properties: the appliqué region provides visual matching and contact hiding, while the adhesive region provides bonding strength. This local differentiation resolves the contradiction by allowing each area to excel at its designated function.
2Shape
If the appliqué covers the entire fourth surface, then the visual appearance is improved, but the adhesive cannot attach to the mirror element and carrier
Solution Approach 1:
The fourth surface is segmented into an appliqué-covered area for visual purposes and an exposed adhesive area for reliable attachment. This segmentation ensures that the adhesive maintains direct contact with both the mirror element and carrier without being blocked by the appliqué.
Solution Approach 2:
The adhesive function is extracted from beneath the appliqué and placed in a separate, exposed region. This allows the adhesive to perform its bonding function independently while the appliqué provides its visual function, eliminating the conflict between coverage and attachment.
3Strength
If adhesive is placed in openings of the appliqué, then bond strength is improved, but the visual match between appliqué and adhesive becomes difficult to achieve
Solution Approach 1:
The adhesive is formulated to visually replicate the appearance of the printed appliqué when viewed through the transmissive regions of the mirror element. This visual copying allows the adhesive to be seen in the openings without creating a noticeable mismatch, while still providing the necessary bonding strength.
Solution Approach 2:
The adhesive's optical properties are adjusted to match the color and appearance characteristics of the printed appliqué. This color matching ensures that even when the adhesive is visible through the transmissive regions, it creates a uniform visual appearance rather than a distracting mismatch.
4Reliability
If the mirror element is fully supported by adhesive, then structural reliability is improved, but the visual appearance is compromised by visible adhesive
Solution Approach 1:
The support function is segmented from the visual presentation function. The adhesive provides structural support in specific locations where it is either hidden or visually matched to the appliqué, while the appliqué maintains the visual appearance in the transmissive regions. This segmentation allows both structural reliability and aesthetic appearance to be achieved simultaneously.
Data Source
AI summary
An electro-optic assembly is disclosed. The assembly comprises a front substrate having a first surface and a second surface substantially parallel to the first surface; a rear substrate spaced from and substantially parallel to the front substrate. The rear substrate comprises a third surface and a fourth surface substantially parallel to the third surface. The assembly further comprises an electrical contact for providing an electrical connection to an electrode in proximity to an electro-optic material and an appliqué layer. The appliqué layer is on at least a portion of the fourth surface and forms a contact-obscuring.