Molded Vanity Mirror Frame with Integrated Transmissive Lighting
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Solution Overview
Problem
Conventional automotive vanity mirror and light assemblies have a complex design with multiple components, making them difficult to manufacture and aesthetically pleasing, while also seeking to reduce the number of components and simplify the manufacturing process.
Innovation Solution
A vanity assembly with a frame and a reflective film molded together to define a reflector and partially transmissive portions, incorporating a lighting device behind the partially transmissive portion to provide vanity lighting, which is integrated into the vehicle visor, using a method that involves molding the frame to the reflective film and installing the lighting device to emit light through the reflective film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional vanity mirror assembly with multiple components (frame, glass mirror, lenses, light sources) is used, then the assembly provides functional vanity lighting and reflection, but the design becomes complex and difficult to manufacture
Solution Approach 1:
The patent merges multiple separate components (frame, reflective film, lighting device housing) into a single integrated molded assembly. The frame is molded directly to the reflective film, creating a unified structure that eliminates the need for separate assembly steps and reduces the total component count while maintaining all necessary functions.
Solution Approach 2:
The molded frame structure serves multiple functions simultaneously: it provides structural support, houses the lighting device, and integrates with the reflective film to create the mirror assembly. This multi-functionality reduces the need for separate specialized components for each function.
2Device complexity
If multiple separate components (frame, glass mirror, lenses, light sources) are assembled to form vanity assembly, then the assembly can be manufactured with standard components, but the final assembly becomes aesthetically less pleasing and more complex
Solution Approach 1:
The integration of the frame and reflective film into a single molded piece creates seamless joints and uniform surfaces that are aesthetically superior to assembled components. The molded construction eliminates visible seams, gaps, and alignment issues that would result from assembling separate parts.
3Productivity
If conventional assembled vanity assembly is used, then the components can be sourced separately, but the manufacturing process becomes more difficult and time-consuming
Solution Approach 1:
The reflective film is positioned and molded onto the frame structure in advance during the molding process, rather than being attached separately after frame fabrication. This preliminary integration of components during the primary manufacturing process eliminates subsequent assembly steps and improves overall manufacturing 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
The solution results in an aesthetically pleasing, easy-to-manufacture vanity assembly with a reduced number of components, achieving a durable and lightweight design with integrated lighting, enhancing user experience by providing sufficient lighting for the mirror in low ambient conditions.
Implementation Method 1
a reflective film molded to the frame to define a reflector portion and a partially transmissive portion
Implementation Method 2
a lighting device located behind the partially transmissive portion of the reflective film to provide vanity lighting passing through the partially transmissive portion
Data Source
AI summary
A vanity mirror and light assembly is provided for use on a vehicle visor. The vanity assembly includes a clear frame molded to a reflective film to define a reflector portion and a partially transmissive portion. The assembly also includes a lighting device located behind the partially transmissive portion of the reflective film to provide a vanity light passing through the partially transmissive portion. A method of forming the vanity assembly in a mold is also provided.