Rain sensor mounting system

• US 20030126924A1
• Filed: 01/21/2003
• Published: 07/10/2003
• Est. Priority Date: 01/07/1998
• Status: Active Grant

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Lynam, Niall R.
• Granted Patent: US 6,968,736 B2
• Time in Patent Office: Days
• US Class Current: 73/170.17
• CPC Class Codes: B60R 1/04 mounted inside vehicle B60R1/025, B60R1/08 take precedence
• CPC Class Codes: B60R 1/12 Mirror assemblies combined with other articles, e.g. clocks
• CPC Class Codes: B60R 11/0241 for telephones
• CPC Class Codes: B60R 11/0247 for microphones or earphones
• CPC Class Codes: B60R 2001/1223 with sensors or transducers
• CPC Class Codes: B60R 2011/0026 Windows, e.g. windscreen
• CPC Class Codes: B60R 2011/0033 Rear-view mirrors
• CPC Class Codes: B60S 1/0822 characterized by the arrangement or type of detection means
• CPC Class Codes: B60S 1/0833 Optical rain sensor
• CPC Class Codes: B60S 1/0881 characterized by the attachment means on the windshield
• CPC Class Codes: B60S 1/0885 the sensor being integrated in a rear-view mirror module
• CPC Class Codes: G02B 2027/0118 comprising devices for improving the contrast of the display / brillance control visibility
• CPC Class Codes: G02B 2027/012 comprising devices for attenuating parasitic image effects
• CPC Class Codes: G02B 6/00 Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings

Abstract

A mount for mounting a rain sensor includes a housing having an access opening on first side and a port on second side for positioning adjacent an inner surface of the vehicle windshield. The second side is adapted for mounting to a vehicle windshield, for example by a layer of adhesive which is interposed between the housing and the windshield. Optionally, the housing includes an access opening and a cover, which and covers the access opening. A mirror mounting button is provided on either the housing or the cover for mounting a rearview mirror assembly to the mount. A biasing member is supported in the housing and is interposed between the first side of the housing and a rain sensor positioned in the housing, which urges a detecting surface of the rain sensor to project through the port and to optically couple the rain sensor to the vehicle windshield for detecting moisture on an outer surface of the vehicle windshield. The biasing member may comprise, for example, a helical spring or a urethane disc.

Claims

1. A rain sensor mounting assembly for mounting a rain sensor to a vehicle windshield, said assembly comprising:

a first mounting member adapted to mount to the vehicle windshield and to receive a rain sensor module, said first mounting member positioning said rain sensor module adjacent an inner surface of the vehicle windshield;

said rain sensor module comprising a housing and a rain sensor having a detecting surface, said rain sensor being contained in said module, said rain sensor module being adapted to engage said first mounting member for mounting said rain sensor module to the windshield;

a biasing member provided in said rain sensor module, said biasing member for urging said detecting surface of said rain sensor to optically couple to the inner surface of the vehicle windshield for detecting moisture on the outer surface of the vehicle windshield; and

a second mounting member provided on said rain sensor module for releasably mounting a rearview mirror assembly to said module.

2. The rain sensor mounting assembly of claim 1, wherein said first mounting member and said second mounting member are generally aligned along a common axis when said rain sensor module is mounted to the vehicle windshield in order to provide a mounting of a rearview mirror assembly to said module generally coaxial with the mounting of said module to the windshield.

3. The rain sensor mounting assembly of claim 1, wherein said first mounting member encompasses an opening, and wherein said biasing member urges said detecting surface of said rain sensor to optically couple to the inner surface of the windshield at said opening of said first mounting member.

4. The rain sensor mounting assembly of claim 3, wherein said first mounting member comprises an annular member and with said opening comprising a central opening in said annular member.

5. The rain sensor mounting assembly of claim 1, wherein said second mounting member provides a breakaway mounting for the rearview mirror assembly to said rain sensor module.

6. The rain sensor mounting assembly of claim 5, wherein said second mounting member comprises a mirror mounting button fabricated of one of a metal and a polymer.

7. The rain sensor mounting assembly of claim 6, wherein said metal comprises one of a steel, a sintered steel, an aluminum, a zinc, a titanium, and a nickel material.

8. The rain sensor mounting assembly of claim 6, wherein said polymer comprises one of a nylon, an ABS, a polyolefin, and an engineering resin material.

9. The rain sensor mounting assembly of claim 5, wherein said rearview mirror assembly comprises a double pivot joint support arm.

10. The rain sensor mounting assembly of claim 1, wherein said biasing member comprises a resilient polymer material.

11. The rain sensor mounting assembly of claim 10, wherein said resilient polymer material comprises one of a rubber, a silicone, a urethane, an elastomeric, and a vinyl material.

12. The rain sensor mounting assembly of claim 10, wherein said resilient polymer material comprises an internal structure of said housing.

13. The rain sensor mounting assembly of claim 1, wherein said detecting surface of said rain sensor comprises a resilient optical material.

14. The rain sensor mounting assembly of claim 13, wherein said optical material comprises one of a silicone and a plasticized polymer material.

15. The rain sensor mounting assembly of claim 1 wherein said rain sensor includes a light emitter and a light detector for detecting presence of moisture on the vehicle windshield.

16. The rain sensor mounting assembly of claim 1, wherein said rain sensor module includes electronic circuitry for generating an electrical signal indicative of detection of moisture on the vehicle windshield.

17. The rain sensor mounting assembly of claim 16, wherein said rain sensor comprises electronic circuitry.

18. The rain sensor mounting assembly of claim 1, wherein said housing is fabricated of one of a rigid metal and a rigid polymer material.

19. The rain sensor mounting assembly of claim 1, wherein said housing is fabricated of a polymer material and said second mounting member is fabricated of a metal material.

20. The rain sensor mounting assembly of claim 1, wherein said second mounting member is provided on said housing.

21. The rain sensor mounting assembly of claim 20, wherein said second mounting member is provided on said housing by an integral molding operation.

22. The rain sensor mounting assembly of claim 1, wherein said second mounting member and said rain sensor module comprise a unitary construction.

23. The rain sensor mounting assembly of claim 22, wherein said unitary construction further comprises said rain sensor.

24. The rain sensor mounting assembly of claim 1, wherein said rain sensor module received on said first mounting member has a footprint less than about four square inches.

25. The rain sensor mounting assembly of claim 24, wherein said rain sensor received on said first mounting member has a footprint less than about two square inches.

26. The rain sensor mounting assembly of claim 1, wherein said first mounting member includes a layer of adhesive for mounting said first mounting member to the vehicle windshield.

27. The rain sensor mounting assembly of claim 26, wherein said adhesive comprises one of a polyvinyl butyral material, an epoxy material, a urethan material, an acrylic material and a silicone material.

28. The rain sensor mounting assembly of claim 26, wherein said layer of adhesive includes an opening whereby said detecting surface of said rain sensor directly contacts the vehicle windshield.

29. The rain sensor mounting assembly of claim 26, wherein said detecting surface of said rain sensor contacts said layer.

30. The rain sensor mounting assembly of claim 1, wherein said biasing member comprises a spring element.

31. The rain sensor mounting assembly of claim 30, wherein said spring element comprises one of a helical spring element and a leaf spring element.

32. The rain sensor mounting assembly of claim 1 wherein said biasing member comprises a flexible polymer.

33. The rain sensor mounting assembly of claim 1, wherein said biasing member comprises a urethane disc.

34. The rain sensor mounting assembly of claim 1, wherein said housing substantially covers and conceals said first mounting member from view from the interior cabin of the vehicle.

35. The rain sensor mounting assembly of claim 1, wherein said module further includes a second sensor for detecting moisture on the inner surface of the vehicle windshield.

36. The rain sensor mounting assembly of claim 1, wherein said second mounting member provided on said rain sensor module is adapted for releasably mounting a prismatic rearview mirror assembly to said rain sensor module.

37. The rain sensor mounting assembly of claim 1, wherein said second mounting member provided on said rain sensor module is adapted for releasably mounting an electrochromic rearview mirror assembly to said rain sensor module.

38. A rain sensor module assembly for attachment to a vehicle windshield, said rain sensor module assembly comprising:

a housing, said housing having a first end adapted to releasably attach to a support mounted to the inner surface of the vehicle windshield;

a rain sensor having a detecting surface, said rain sensor contained in said housing;

a biasing member provided in said module, said biasing member for urging said detecting surface of said rain sensor to optically couple to the inner surface of the vehicle windshield for detecting moisture on the outer surface of the vehicle windshield; and

said housing having an opposing second end provided with a mirror mounting button for releasably mounting a rearview mirror assembly to said module.

39. The rain sensor module assembly according to claim 38, wherein said first end includes a layer of adhesive for mounting said housing to the vehicle windshield.

40. The rain sensor module assembly according to claim 39, wherein said adhesive comprises one of a polyvinyl butyral material, an epoxy material, a urethane material, an acrylate material, an acrylic material, and a silicone adhesive material.

41. The rain sensor module assembly according to claim 39, wherein said layer includes an opening, said rain sensor extending through said opening of said layer to position said detecting surface of said rain sensor for directly contacting the windshield.

42. The rain sensor module assembly of claim 39, wherein said detecting surface of said rain sensor contacts said layer.

43. The rain sensor module assembly to claim 38, wherein said mirror mounting button is integrally formed with said housing.

44. The rain sensor module assembly according to claim 38, wherein said mirror mounting button is releasably secured to said housing.

45. The rain sensor module assembly of claim 38, wherein said biasing member comprises one of a helical spring element and a leaf spring element.

46. The rain sensor module assembly according to claim 38, wherein said biasing member comprises a urethane disc.

47. The rain sensor module assembly of claim 38 wherein said mirror mounting button is adapted for releasably mounting a prismatic rearview mirror assembly to said module assembly.

48. The rain sensor module assembly of claim 38 wherein mirror mounting button is adapted for releasably mounting an electrochromic rearview mirror assembly to said module assembly.

49. A rain sensor mounting assembly comprising:

a mounting member encompassing an opening, said mounting member being adapted to mount on an inner surface of a vehicle windshield;

a housing having a first end adapted to releasably attach to said mounting member;

a rain sensor having a detecting surface, said rain sensor contained in said housing;

a biasing member provided in said housing, said biasing member for urging said detecting surface of said rain sensor to optically couple to the inner surface of the vehicle windshield for detecting moisture on an outer surface of the vehicle windshield; and

said housing having an opposing second end, said second end including a mirror mounting button for releasably mounting a rearview mirror assembly to said rain sensor mounting assembly.

50. The rain sensor mounting according to claim 49 wherein said mounting member includes a layer of adhesive for mounting said mounting member to the vehicle windshield.

51. The rain sensor mounting according to claim 49 wherein said mounting member includes an outer peripheral portion, said housing releasably engaging said peripheral portion of said mounting member.

52. The rain sensor mounting according to claim 50, wherein said layer of adhesive includes a transverse opening, said rain sensor extending through said transverse opening of said layer of adhesive for directly contacting the inner surface of the windshield.

53. The rain sensor mounting according to claim 49, wherein said housing includes a footprint, said footprint being less than the about four square inches.

54. The rain sensor mounting according to claim 49, wherein said housing includes a footprint, said footprint being less than the about two square inches.

55. The rain sensor mounting according to claim 49, wherein said housing includes a footprint, said footprint being less than the about one square inch.

56. The rain sensor mounting according to claim 49, wherein said first end of said housing substantially covers and conceals said mounting member.

57. The rain sensor mounting assembly of claim 49, wherein said mirror mounting button is adapted for releasably mounting a prismatic rearview mirror assembly to said module assembly to said rain sensor mount assembly.

58. The rain sensor mounting assembly of claim 49, wherein said mirror mounting button is adapted for releasably mounting an electrochromic rearview mirror assembly to said rain sensor mount assembly.

59. A rain sensor mounting assembly for mounting a rain sensor to a vehicle windshield, said rain sensor mounting comprising:

a mounting member adapted for mounting to the inner surface of the vehicle windshield, said mounting member encompassing an opening;

said mounting member adapted to releasably receive a rain sensor module, said rain sensor module comprising a rain sensor having a detecting surface and a housing provided with a mirror mounting button for releasably mounting a rearview mirror assembly to said module, said detecting surface of said rain sensor for optically coupling with the inner surface of the inner surface of the vehicle windshield at said opening of said mounting member when mounted in the vehicle for detecting moisture on the outer surface of the vehicle windshield;

said mounting member and said mirror mounting button generally aligned along a common axis when said module is received by said mounting member;

said rearview mirror assembly comprising a rearview mirror housing including a mirror element therein, a support arm connected to said rearview mirror housing, said support arm terminating in a mirror mount adapted to provide a break-away connection to said mirror mounting button of said rain sensor module; and

wherein said support arm is connected to said rearview mirror housing by a pivot joint to permit repositioning of said reflective element and wherein said support arm is connected to said mirror mounting button by a second pivot joint to permit a further range of positions for said rearview mirror reflective element.

60. The rain sensor mounting assembly according to claim 59, wherein said mirror mounting button and said housing comprise a unitary member.

61. The rain sensor mounting assembly according to claim 59, wherein said mounting member includes a layer of adhesive for mounting said housing to the vehicle windshield.

62. The rain sensor mounting assembly according to claim 61, wherein said adhesive comprises one of a polyvinyl butyral material, an epoxy material, a urethane material, an acrylate material, an acrylic material, and a silicone material.

63. The rain sensor mounting assembly according to claim 61, wherein said layer includes a transverse opening, said rain sensor extending through said transverse opening whereby said detecting surface of said rain sensor is positioned for directly contacting the windshield.

64. The rain sensor mounting assembly according to claim 59, wherein said rain sensor module housing includes a footprint, said footprint being less than about four square inches.

65. The rain sensor mounting assembly according to claim 59, wherein said second side of said rain sensor module housing substantially covers and conceals said mounting member.

66. The rain sensor mounting assembly according to claim 59, wherein said mounting member comprises an annular member having a central opening defining said transverse opening, said rain sensor module housing being secured to said annular member, and said rain sensor being positioned in said central opening and being urged for optically coupling said detecting surface of said rain sensor to the vehicle windshield for detecting moisture on an outer surface of the vehicle windshield.

67. The rain sensor mounting assembly of claim 59, wherein said rearview mirror assembly comprises a prismatic rearview mirror assembly.

68. The rain sensor mounting assembly of claim 59, wherein said rearview mirror assembly comprises an electrochromic rearview mirror assembly.

69. A rain sensor assembly for attachment to a vehicle windshield, said rain sensor assembly comprising:

a rain sensor module housing a rain sensor, said rain sensor having a detecting surface, said detecting surface being exposed at a first end of said module so as to optically couple to the inner surface of the vehicle windshield when said module is mounted in the vehicle for detecting moisture on the outer surface of the vehicle windshield;

a mirror mounting button positioned on said module at a second end opposing said first end; and

wherein said detecting surface and said mirror mounting button are 10 substantially aligned along a common axis when said rain sensor module is mounted in the vehicle.

70. The rain sensor assembly according to claim 69, wherein said rain sensor module includes a footprint, said footprint being less than about four square inches.

71. The rain sensor assembly according to claim 69, wherein said rain sensor module includes a footprint, said footprint being less than about two square inches.

72. The rain sensor assembly according to claim 69, wherein said rain sensor module includes a footprint, said footprint being less than about one square inch.

73. The rain sensor assembly according to claim 69, further comprising a prismatic rearview mirror assembly, said prismatic rearview mirror assembly releasably engaging said mirror mounting button.

74. The rain sensor assembly according to claim 73, further comprising a support arm supporting said prismatic rearview mirror assembly on said rain sensor module housing, said support arm including a first ball and socket connection to said prismatic rearview mirror assembly and a second ball and socket connection to said mirror mounting button.

75. The rain sensor assembly of claim 69, further comprising an electrochromic rearview mirror assembly, said electrochromic rearview mirror assembly releasably engaging said mirror mounting button.

76. The rain sensor assembly according to claim 75, further comprising a support arm supporting said electrochromic rearview mirror assembly on said rain sensor module housing, said support arm including a first ball and socket connection to said electrochromic rearview mirror assembly and a second ball and socket connection to said mirror mounting button.

77. The rain sensor assembly according to claim 69, wherein said module is adapted to attach a rain sensor mounting member, said rain sensor mounting member for attaching to the inner surface of the windshield.

78. The rain sensor assembly according to claim 77, wherein said rain sensor mounting module comprises a member having an opening, said rain sensor module housing being secured to said rain sensor mounting member, and said rain sensor being positioned in said opening and being urged for optically coupling said detecting surface of said rain sensor to be vehicle windshield for detecting moisture on an outer surface of the windshield.