Sandwich Structure Exterior Rear View Assembly
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Solution Overview
Problem
Existing exterior rear view systems for road vehicles are often bulky, heavy, and inefficient, with limited design flexibility and recyclability, and they do not effectively cover the driver's blind spots without increasing wind resistance.
Innovation Solution
A sandwich structure exterior rear view assembly comprising a core element made of glass fiber-free thermoplastic polymer and metal plate elements, which provides high strength and stiffness-to-weight ratio, allowing for a stable, versatile, and recyclable design that can articulate with the vehicle body, integrate electronic components, and reduce wind resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional exterior rear view systems are used, then they can provide basic rear view functionality, but they become bulky and heavy, increasing wind resistance
Solution Approach 1:
The patent employs a sandwich structure combining aluminum plate elements with a polypropylene core element, creating a composite material assembly that achieves high strength-to-weight ratio and stiffness-to-weight ratio, directly reducing weight while maintaining structural integrity and reducing wind resistance
Solution Approach 2:
The exterior rear view assembly is divided into distinct functional components: plate elements for structural support, core element for spacing and housing, and coupling sections for articulation. This segmentation allows each component to be optimized independently for weight and function, reducing overall assembly bulk
2Adaptability or versatility
If traditional exterior rear view systems are used, then they can provide basic functionality, but they have limited design flexibility
Solution Approach 1:
The sandwich structure assembly serves multiple functions simultaneously: the plate elements provide structural support and mounting surfaces, the core element provides spacing and houses electronic components, and the integrated coupling sections enable articulation. This multi-functionality within a unified structure enhances design flexibility without proportionally increasing complexity
Solution Approach 2:
The patent utilizes the third dimension by creating a spaced sandwich structure with the core element thickness (10-50mm) providing vertical separation between plate elements. This dimensional approach allows integration of electronic components within the core, adding functional capacity without increasing horizontal footprint
3Ease of manufacture
If traditional exterior rear view systems are used, then they can be manufactured, but recyclability is poor
Solution Approach 1:
The assembly is designed as separable components (plate elements, core element, coupling sections) that can be easily disassembled at end-of-life, enabling material recovery and recycling. The modular design allows different materials to be processed separately through appropriate recycling streams
Solution Approach 2:
The sandwich structure is designed for easy disassembly and material recovery. The aluminum plate elements can be recovered through metal recycling programs, while the polypropylene core element can be processed through plastic recycling streams, maximizing material recovery and minimizing waste
4Strength
If glass fiber reinforced materials are used, then strength is improved, but recyclability deteriorates
Solution Approach 1:
The patent uses aluminum plate elements (inherently strong and recyclable) combined with a polypropylene foam core element. This composite structure achieves the required structural strength through the aluminum components while the thermoplastic polypropylene core maintains recyclability through melting and reprocessing capabilities
Solution Approach 2:
The core element uses thermoplastic polypropylene with specific density parameters (0.9-1.05 g/cm³) and thickness parameters (10-50mm) that provide structural support while maintaining recyclability. The material parameters are optimized to achieve required strength without glass fiber reinforcement
Data Source
AI summary
Exterior rear view assembly for road vehicles and method of manufacturing an exterior rear view assembly for road vehiclesThe present invention provides an exterior rear view assembly for road vehicles. The assembly comprises: a first plate element; a second plate element having essentially a similar form as and extending essentially in parallel to the first plate element; and a core element arranged sandwiched between the first plate element and the second plate element, wherein the first plate element, the core element and the second plate element together form a joint part comprising a coupling section configured to be coupled to a vehicle body in an articulated manner. Furthermore, the invention provides a corresponding method of manufacturing an exterior rear view assembly for road vehicles.