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.
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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.
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Citations
9 Claims
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1. A method of manufacturing a carrier for a rearview mirror assembly, comprising the steps of:
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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)
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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:
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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.
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7. A method of manufacturing an injection molded carrier for a rearview mirror assembly, comprising the steps of:
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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)
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Specification