Fillable and stiffened rearview mirror assembly
First Claim
Patent Images
1. A method of manufacturing a carrier for a rearview mirror assembly, comprising the steps of:
- providing a blank to be melted;
heating the blank to form a molten blank;
forcing air into the molten blank to form a blowmolded carrier having a hollow space therein;
inserting a stiffening structure in the blowmolded carrier;
cooling the blowmolded carrier to achieve form stability; and
inserting a foam element in the hollow space.
3 Assignments
0 Petitions
Accused Products
Abstract
A fillable rearview mirror assembly and method of molding a carrier for the assembly are provided. The mirror assembly has a hollow carrier that can be at least partially filled with a material having a density different than that of the carrier. A mirror can be attached to the carrier and the carrier attached to the vehicle.
-
Citations
16 Claims
-
1. A method of manufacturing a carrier for a rearview mirror assembly, comprising the steps of:
-
providing a blank to be melted;
heating the blank to form a molten blank;
forcing air into the molten blank to form a blowmolded carrier having a hollow space therein;
inserting a stiffening structure in the blowmolded carrier;
cooling the blowmolded carrier to achieve form stability; and
inserting a foam element in the hollow space. - View Dependent Claims (2, 3, 4, 5)
-
-
6. A method of manufacturing a stiffened, extrusion blowmolded carrier for a rearview mirror assembly, the carrier having a hollow space therein, comprising the steps of:
-
providing a plastic blank to be melted;
heating the blank to form a molten blank;
forcing the molten blank to form a continuous hollow carrier;
inserting a stiffening rib in the hollow space;
affixing the stiffening rib in the hollow space to the carrier;
cooling the carrier to achieve form stability;
injecting a plastic foam in the hollow space; and
encapsulating the rib with the plastic foam.
-
-
7. A method of manufacturing an injection molded carrier for a rearview mirror assembly, comprising the steps of:
-
providing a plastic blank to be melted;
heating the blank to form a molten blank;
forming by injection the molten blank into the form of a carrier having a hollow space therein, the hollow space having a first part and a second part;
inserting stiffening tubes and ribs in the hollow space;
affixing the tubes and ribs in the hollow space to the carrier;
cooling the carrier to achieve form stability;
injecting a plastic foam in at least the first part of the hollow space;
encapsulating the tubes and ribs at least partially with the foam; and
injecting a granulate in at least the second part of the hollow space. - View Dependent Claims (8)
-
-
9. A method of manufacturing a rearview mirror assembly for a vehicle, the method comprising the steps of:
-
providing a plastic carrier having a first hollow space therein, the first hollow space extending substantially through the majority of the carrier, the carrier having a first and a second side;
attaching a mirror housing to the first side of the carrier;
affixing a carrier arm having a proximal end and a distal end to the vehicle, the proximal end affixed to the second side of the carrier opposite the mirror housing, the distal end extending away from the proximal end and configured to attach the carrier to the vehicle, the arm having a second hollow space therein;
affixing a mirror element to the mirror housing; and
filling the first hollow space of the carrier and the second hollow space of the carrier arm with a fill material. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
-
Specification