Spring-Loaded Connector for Mirror Assembly Electrical Connection
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Solution Overview
Problem
Existing interior rearview mirror assemblies face challenges in efficiently and reliably connecting electrical circuitry to the conductive coatings of variable reflectance reflective elements, often requiring soldering and complex wiring, which can be cumbersome and prone to errors.
Innovation Solution
The implementation of spring-loaded electrical connectors that bias into contact with conductive traces and pads at the rear of the reflective element, establishing a secure and reliable electrical connection between circuitry on a printed circuit board and the conductive coatings of the reflective element, eliminating the need for soldering and wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering and complex wiring are used to connect electrical circuitry to conductive coatings, then reliable electrical connection is achieved, but assembly complexity and difficulty increase
Solution Approach 1:
The patent replaces the traditional soldering process (thermal/mechanical joining) with a spring-loaded mechanical connector system. The spring-loaded electrical connectors provide reliable electrical connection through mechanical contact forces, eliminating the need for soldering irons, flux, and complex wiring harnesses, thereby reducing assembly complexity while maintaining connection reliability.
Solution Approach 2:
The patent extracts and eliminates the soldering step from the assembly process by introducing spring-loaded connectors that can be installed through simple insertion and compression. This removes the need for specialized soldering equipment and processes, simplifying the overall assembly procedure while maintaining reliable electrical connections.
2Reliability
If soldering is used to connect electrical circuitry, then secure electrical connection is achieved, but assembly time and productivity decrease
Solution Approach 1:
The spring-loaded electrical connectors are pre-assembled with the circuit board or reflective element sub-assembly, allowing the electrical connection to be established in advance. During final assembly, the pre-assembled units are simply joined together, eliminating the need for time-consuming soldering operations at the final assembly stage and significantly improving productivity.
3Reliability
If complex wiring and soldering are required, then electrical connection is established, but ease of manufacture and automation decrease
Solution Approach 1:
The patent divides the mirror assembly into modular sub-assemblies (reflective element, circuit board, housing) with spring-loaded connectors at the interfaces. Each sub-assembly can be manufactured and tested independently, then quickly assembled together through simple connector engagement. This segmentation enables easier manufacturing and facilitates automated assembly processes while ensuring reliable electrical connections at each interface.
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 enhances the assembly process by providing a secure, solderless connection that maintains electrical contact, facilitating easier and more automated assembly of mirror reflective element sub-assemblies, and allows for adjustable mounting configurations.
Implementation Method 1
a spring-loaded electrical connector configured to electrically connect between circuitry on a circuit element and electrically conductive elements established at a rear portion of the mirror reflective element. The spring-loaded electrical connector is urged or biased into electrical contact with the electrically conductive traces and electrically conductive elements as the back plate is attached
Data Source
AI summary
A vehicular rearview mirror assembly includes an electro-optic reflective element and a back plate, with a spring-loaded electrical connector disposed in a passageway of the back plate. The spring-loaded electrical connector is spring-biased toward an extended state and compressible toward a compressed state. The reflective element has an electrically conductive element established at the rear surface and in electrical connection with a conductive coating of the reflective element. A circuit element is disposed at the back plate and has an electrically conductive trace electrically connected to control circuitry. With the back plate attached at the reflective element and with the circuit element attached at the back plate, the spring-loaded electrical connector is compressed toward the compressed state and electrically connects the electrically conductive trace at the circuit element and the electrically conductive element at the reflective element.