Fillable and stiffened rearview mirror assembly

• US 20050057832A1
• Filed: 10/25/2004
• Published: 03/17/2005
• Est. Priority Date: 05/05/2000
• Status: Active Grant

• Current Assignee: Lang-Mekra North America LLC
• Original Assignee: Lang-Mekra North America LLC
• Inventors: Popp, Albrecht, Lang, Heinrich
• Granted Patent: US 7,445,734 B2
• Time in Patent Office: Days
• US Class Current: 359/871
• CPC Class Codes: B60R 1/0605 specially adapted for mounting on trucks, e.g. by C-shaped support means
• CPC Class Codes: Y10S 359/90 Methods

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.

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.

2. The method as in claim 1, further comprising the step of providing the blank with varying thicknesses to achieve varying thicknesses in the carrier.

3. The method as in claim 1, wherein the hollow space is a plurality of hollow bubbles.

4. The method as in claim 1, wherein the stiffening structure is one of grid-like ribs, tubes, or combinations thereof.

5. The method as in claim 1, wherein the foam element is shaped complementary to the stiffening structure, the hollow space, and combinations thereof.

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.

8. The method as in claim 7, further comprising the step of forming one of the first and second parts to have a plurality of hollow bubbles suspended in a portion of the hollow space and stabilized carrier.

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