Rearview Mirror Touch Sensor Casing for Simpler Assembly
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Solution Overview
Problem
Existing rearview mirror assemblies lack integrated touch sensor inputs that provide seamless integration with capacitive touch technology, leading to complex assembly processes and increased risk of component damage during manufacturing.
Innovation Solution
The integration of capacitive touch sensors within a sensor casing, formed by screen printing circuitry on a thermoformable film and overmolding with a polymeric material, creates a unitary in-mold structural electronic component that is snap-attached to the mirror head, reducing assembly complexity and enhancing ingress protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If capacitive touch sensors are integrated within the mirror head structure, then the user interface is enhanced and styling flexibility is improved, but the assembly process becomes more complex and component damage risk increases
Solution Approach 1:
The patent combines the touch sensor assembly with the mirror head structure by snap-fitting the sensor casing into the mirror head. This integration merges previously separate components (touch sensors, sensor casing, mirror head) into a unified assembly, enhancing the user interface while managing complexity through modular integration rather than complete monolithic construction.
Solution Approach 2:
The touch sensors are encapsulated within the sensor casing, which is then snap-fitted into the mirror head structure. This nested arrangement places the sensor casing inside the mirror head, creating a compact integrated unit that improves styling flexibility while containing complexity within a modular nested structure.
2Ease of manufacture
If multiple separate components are used for touch sensors and mirror head, then manufacturing flexibility is maintained, but assembly complexity increases and ingress protection is reduced
Solution Approach 1:
The sensor casing is snap-fitted into the mirror head to form an integrated assembly, merging previously separate components. This integration improves ingress protection by creating a more unified structure with reduced gaps and interfaces where contaminants could penetrate, while maintaining manufacturing flexibility through the modular snap-fit connection that allows separate fabrication.
Solution Approach 2:
The patent applies different properties to different parts: the sensor casing provides a sealed environment for the touch sensors, while the mirror head structure provides structural support and integration. This local differentiation of qualities (sealing vs. structural) enables both good ingress protection and manufacturing flexibility by optimizing each component for its specific function.
3Strength
If touch sensors are encapsulated within a sensor casing, then protection against damage is improved, but the number of components increases
Solution Approach 1:
The touch sensors are nested within the sensor casing, which is then nested within the mirror head structure. This nested arrangement provides protection for the delicate touch sensors against damage while integrating the assembly into the existing mirror head. The nesting reduces the effective component count by creating hierarchical containment rather than separate discrete assemblies.
Solution Approach 2:
The sensor casing acts as a protective shell that encapsulates the touch sensors. This flexible yet protective casing provides damage protection for the fragile electronic components while maintaining a compact form factor that integrates smoothly into the mirror head structure, balancing protection with space efficiency.
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 approach simplifies assembly, reduces component count, and enhances styling flexibility while providing improved protection against damage and a seamless user interface with capacitive touch sensors.
Implementation Method 1
When a conductor, such as a finger, approaches or contacts an outer surface of the capacitive touch sensors 28, the capacitive coupling between the conductor and the capacitive touch sensors 28 changes, thereby providing a user input.
Data Source
AI summary
A vehicular interior rearview mirror assembly includes a mirror head adjustable about a mounting base that is configured to mount the vehicular interior rearview mirror assembly at an interior portion of a vehicle. The mirror head accommodates a mirror casing and a mirror reflective element. A sensor casing is formed separate from the mirror casing and includes a plurality of capacitive touch sensors encapsulated within a wall structure of the sensor casing. The sensor casing is attached to the mirror casing such that an outer surface of the wall structure includes an outer surface of the mirror head. A system of the vehicle is controlled responsive to a user input at a portion of the outer surface of the wall structure of the sensor casing that corresponds to one or more of the plurality of capacitive touch sensors.