Shaped Rearview Mirror Substrate Edge Concealment
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Solution Overview
Problem
Traditional rearview mirror assemblies face challenges in hiding the edges of substrates, especially in frameless designs, which can lead to aesthetically unacceptable appearances and reduced forward vision due to the exposure of substrate edges, and glare issues from headlamps at night.
Innovation Solution
A rearview mirror assembly with a front and rear substrate having shaped edges, where the rear substrate is made thinner than the front substrate, and a perimeter seal is used to hide the edges, along with a conductive element and electro-optic medium, and a surface coating to enhance aesthetics and protect from UV radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional rearview mirror assemblies use frameless design, then device complexity is reduced, but substrate edges become exposed leading to aesthetically unacceptable appearance
Solution Approach 1:
The patent introduces a third dimension by making the rear substrate thinner than the front substrate, creating a stepped configuration. This dimensional change allows the rear substrate edge to be positioned behind the front substrate edge, hiding it from view while maintaining frameless design simplicity
Solution Approach 2:
The patent employs asymmetric substrate thickness where the front substrate is thicker than the rear substrate. This asymmetry creates an overlapping edge configuration that aesthetically conceals the rear substrate edge while preserving the frameless design's structural simplicity
2Ease of manufacture
If substrate edges are exposed in frameless design, then manufacturing is simplified, but forward vision is reduced due to exposed edges
Solution Approach 1:
By varying the thickness of substrates in the third dimension, the patent enables the rear substrate to be positioned behind the front substrate edge, effectively reducing the visible edge area that obstructs forward vision while keeping the frameless manufacturing approach
3Device complexity
If substrate edges are exposed at night, then structural simplicity is maintained, but glare from headlamps increases
Solution Approach 1:
The thickness variation creates an overlapping edge structure where the rear substrate is positioned behind the front substrate. This geometric arrangement blocks direct line-of-sight to the rear substrate edge, reducing headlamp glare reflection while preserving structural simplicity
Solution Approach 2:
The front substrate acts as an intermediary element that physically blocks the view of the rear substrate edge from the driver's perspective. This intermediary structure reduces glare without adding complex anti-glare mechanisms
4Shape
If rear substrate is made thinner, then edge hiding is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies predetermined thickness values for both front and rear substrates during the design phase. By pre-establishing the thickness differential requirement, the manufacturing process can be optimized to achieve the necessary precision without excessive complexity
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
The solution provides a seamless appearance by hiding the substrate edges, reducing glare, and enhancing the mirror's durability and impact resistance, while maintaining effective electrical connectivity and reflectance properties.
Implementation Method 1
an electro-optic medium disposed in the cavity between the front substrate and the rear substrate
Implementation Method 2
a surface coating to enhance aesthetics and protect from UV radiation
Data Source
AI summary
A rearview mirror assembly is provided that includes a front substrate comprising a first surface and a second surface; and a rear substrate comprising a third surface and a fourth surface. The rear substrate defines at least one contact via and the front substrate and the rear substrate define a cavity. The mirror assembly further includes a perimeter seal between the front substrate and the rear substrate; and an electrically conductive element at least partially within said at least one contact via that electrically connects with at least one of the second surface and the third surface. The mirror assembly also includes an electro-optic medium disposed in the cavity. In addition, the front substrate and the rear substrate each has a shaped edge having a continuously arcuate shape. The shaped edges can also be formed by grinding the edges together.