Unitary Side Mirror with Integrated Spotting Portion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing side mirror assemblies for motor vehicles are costly and difficult to maintain due to the need for two separate mirror elements, complex adhesive bonding, and challenges in uniformly heating composite mirrors with heated glass features, which increases production and inventory costs and complicates manufacturing.
Innovation Solution
A unitary side mirror assembly with a main viewing portion and a spotting mirror portion fabricated from a single structure, featuring a flange around the periphery and a backing plate with channels to secure the mirror, allowing for even heat distribution and improved structural strength, reducing the need for separate mirror elements and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate mirror elements are used in composite mirror configuration, then blind zone reduction is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the main mirror and auxiliary mirror into a single unitary mirror element with an integrated flange, eliminating the need for separate mirror components and complex adhesive bonding while maintaining blind zone reduction functionality
Solution Approach 2:
The unitary mirror structure serves multiple functions: it provides the main viewing surface, the convex auxiliary viewing surface for blind zone reduction, and integrates a flange for mounting, consolidating what were previously separate components into one multi-functional element
2Ease of manufacture
If adhesive bonding is used to attach auxiliary mirror, then composite mirror assembly is achieved, but maintenance difficulty and reliability decrease
Solution Approach 1:
The mirror and flange are manufactured as a single integrated unit rather than assembled from separate parts, eliminating adhesive bonding entirely and making the structure maintenance-free while improving reliability
Solution Approach 2:
The unitary mirror element with integrated flange is designed as a single replaceable component that can be easily replaced as a whole unit if needed, simplifying maintenance compared to repairing bonded composite structures
3Reliability
If composite mirror structure is used, then spotting mirror function is achieved, but heating uniformity deteriorates
Solution Approach 1:
The unitary mirror structure with integrated flange allows for uniform heat distribution across the entire mirror surface including the convex portion, eliminating the heating non-uniformity problems associated with composite multi-piece structures
4Reliability
If two mirror elements are used, then blind spot coverage is improved, but inventory cost increases
Solution Approach 1:
The unitary mirror element consolidates what were previously two separate mirror components into one single part, reducing inventory complexity and cost while maintaining the blind spot coverage functionality through the integrated convex auxiliary viewing surface
Data Source
AI summary
A mirror assembly for a motor vehicle includes a base that is fixedly secured to the motor vehicle. A housing is fixedly secured to the base. The housing defines an opening. A mirror is operatively secured to the housing at the opening. The mirror defines a main viewing portion and a spotting mirror portion wherein the main viewing portion and the spotting mirror portion are fabricated from a unitary structure. The mirror is a reflective element and defines a main viewing portion of one curvature and a spotting mirror portion for viewing the blind spot which is defined by having a radius of curvature less than the main viewing portion. Both viewing portions of the mirror are integral to one unitary structure that is fabricated from sheet metal such as steel, stainless steel, or aluminum that may optionally be chrome plated, polished, or anodized.