REARVIEW MIRROR CONSTRUCTED FOR EFFICIENT ASSEMBLY

• US 20060268410A1
• Filed: 07/13/2006
• Published: 11/30/2006
• Est. Priority Date: 05/21/2001
• Status: Active Grant

• Current Assignee: Bradley L. Busscher, Bradley L. Northman, Daniel J. Bostwick, Edward L. Denave, Gregory A. Bosch, John K. Roberts, Kenton J. Ypma, Randall J. Beute, Randall S. Braun, Timothy A. Bonardi, Wayne M. Jordan
• Original Assignee: Bradley L. Busscher, Bradley L. Northman, Daniel J. Bostwick, Edward L. Denave, Gregory A. Bosch, John K. Roberts, Kenton J. Ypma, Randall J. Beute, Randall S. Braun, Timothy A. Bonardi, Wayne M. Jordan
• Inventors: Roberts, John K., Braun, Randall S., Ypma, Kenton J., Busscher, Bradley L., DeNave, Edward L., Bosch, Gregory A., Beute, Randall J., Jordan, Wayne M., Bonardi, Timothy A., Northman, Bradley L., Bostwick, Daniel J.
• Granted Patent: US 7,408,694 B2
• Time in Patent Office: Days
• US Class Current: 359/528
• CPC Class Codes: B60Q 1/2665 on rear-view mirrors lighting devices for vehicle interior on or for rear-view mirrors B60Q3/258
• CPC Class Codes: B60R 1/0602 comprising means for cleaning or deicing
• CPC Class Codes: B60R 1/07 by electrically powered actuators
• CPC Class Codes: B60R 1/072 for adjusting the mirror relative to its housing
• CPC Class Codes: B60R 1/088 using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors
• CPC Class Codes: B60R 1/1207 with lamps; with turn indicators
• CPC Class Codes: B60R 2001/1215 with information displays
• CPC Class Codes: G02B 5/08 Mirrors vehicle mirrors involving special optical features B60R1/08
• CPC Class Codes: H05K 1/02 Details
• CPC Class Codes: H05K 1/18 Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/09072 Hole or recess under component or special relationship between hole and component
• CPC Class Codes: H05K 2201/09081 Tongue or tail integrated in planar structure, e.g. obtained by cutting from the planar structure
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10484 Obliquely mounted
• CPC Class Codes: H05K 3/0058 Laminating printed circuit boards onto other substrates, e.g. metallic substrates H05K1/0281 takes precedence

Abstract

A mirror assembly includes a housing, an angularly adjustable power pack, wires for supplying power and mirror angle control, an electrochromic mirror subassembly including a heater, and a turn signal device. The components include individual connectors that plug into a multi-prong connector on the bundle of wires, or that piggyback into each other. Optionally, the heater incorporates an internal wire with end connectors for communicating power to opposite sides of the heater, and also includes layers of light-transmitting/diffusing material for diffusing light passing from the turn signal device through the diffusing material. A printed circuit board fits into a pocket in the panel-shaped carrier, and an integral retainer releasably secures the printed circuit board. The power pack is attached to the carrier via a ring of resilient fingers, and a continuous hoop flange prevents distortion of the carrier and in turn of the glass elements in the mirror subassembly.

Claims

1. A mirror assembly comprising:

a mirror component including first electrical conductors operably connected to the mirror component;

an electrically-operated second component associated with the mirror component and that includes second electrical conductors operably connected to the electrically-operated second component;

a first connector, said first and second electrical conductors operably connected to said first connector; and

a primary wire bundle configured to communicate power to the mirror component and to the electrically-operated second component, the primary wire bundle including a main connector, the first connector engaging and electrically connected to the main connector, whereby the primary wire bundle is configured to communicate power to the mirror component and to the electrically-operated second component.

2. The mirror assembly defined in claim 1 and further comprising a second connector engaging and electrically connected to one of the main connector and the first connector.

3. The mirror assembly defined in claim 1, wherein the electrically-operated second component is a turn signal device adapted to generate a turn signal.

4. The mirror assembly defined in claim 1, wherein the first electrical conductors are electrically connected to a second connector that is connected to the main connector through the first connector.

5. The mirror assembly defined in claim 1, wherein the electrically-operated second component is a heater for heating the mirror component.

6. The mirror assembly defined in claim 5, wherein the main connector has a least six terminals, two of the terminals being connected to a turn signal device, two of the terminals being connected to the mirror component, and two of the terminals being connected to the heater.

7. The mirror assembly defined in claim 1, including a panel-shaped carrier, and wherein the main connector and also the mirror component are attached to the carrier.

8. The mirror assembly defined in claim 1, including a housing with a laterally-extending structural arm that is adapted to support the mirror component on an exterior of a vehicle body.

9. The mirror assembly defined in claim 8, wherein the mirror component is operably supported in the housing for angular adjustment.

10. The mirror assembly defined in claim 9, including a power adjustment device releasably engaging the carrier and supporting the mirror component in an opening in the housing.

11. The mirror assembly defined in claim 1, and further comprising a heater, wherein the second component is a turn signal device, and wherein the first conductors are internally integrated into the heater to provide electrical power from the main connector across the heater to the turn signal device.

12. A mirror comprising:

an mirror subassembly including a panel-shaped carrier with flanges defining a pocket;

a printed circuit board positioned in the pocket; and

a releasable retainer releasably retaining the printed circuit board in the pocket.

13. The mirror defined in claim 12, including a housing with an arm extending from the housing that is configured and adapted for attachment to an exterior of a vehicle.

14. The mirror defined in claim 12, including an electrically operated component, and wherein the circuit board is configured to operate the electrically operated component.

15. The mirror defined in claim 14, and wherein the electrically operated component is a turn signal device.

16. The mirror defined in claim 12, wherein the retainer includes a door for covering a recess in the carrier.

17. The mirror defined in claim 16, wherein the retainer is attached to the carrier by a living hinge.

18. The mirror defined in claim 12, including resilient fingers integrally formed of material contiguous with the carrier and shaped to snappingly engage and secure the retainer.

19. The mirror defined in claim 16, wherein the retainer is integrally formed of material contiguous with the carrier and is attached to the carrier with a living hinge, and including integrally formed catches on the carrier for snappingly engaging the door to retain the door in a closed position.

20. The mirror defined in claim 12, wherein the retainer is integrally molded as part of the carrier.

21. The mirror defined in claim 12, wherein the carrier includes a living hinge connecting the retainer to the carrier and further is made without blind surfaces so that the carrier can be molded with dies not having pulls, slides or other movable components for making blind surfaces.

22. The mirror defined in claim 21, including a first catch on a side of the retainer opposite the living hinge.

23. The mirror defined in claim 22, further comprising a second catch on a side 90°

from the first catch.

24. The mirror defined in claim 12, wherein the circuit board includes light sources for generating visible light.

25. The mirror defined in claim 24, wherein the light sources are positioned to form a pattern suitable for use as a turn signal indicator.

26. The mirror defined in claim 12, wherein the carrier includes a pressure foot in the pocket shaped to prevent looseness and rattling of the circuit board when the retainer is holding the circuit board.

27. A mirror subassembly for use in a rearview mirror assembly having a housing and a power pack attached to the housing and including an angularly adjustable mount, said mirror subassembly comprising:

a mirror subassembly including at least one glass element, and further including a panel-shaped carrier with a front surface shaped to uniformly support the glass element, the panel-shaped carrier including a plurality of resilient retainers arranged in a circle and extending rearwardly from the panel-shaped carrier and engaging the adjustable mount and further including a continuous hoop-shaped wall extending around and spaced radially from the plurality of resilient retainers, the hoop-shaped wall extending from the rear surface and supporting an area around and proximate a base of the plurality of resilient retainers.

28. The mirror subassembly defined in claim 27, wherein the hoop-shaped wall defines a constant radius.

29. The mirror subassembly defined in claim 27, wherein the hoop-shaped wall has a constant height relative to a rear surface of the carrier.

30. The mirror subassembly defined in claim 27, wherein the hoop-shaped wall has constant cross-sectional shape and thickness around the wall'"'"'s entire length.

31. The mirror subassembly defined in claim 27, including marginal material defining an enlarged hole centered inside of the retainers, the marginal material forming a continuous ring inside of the retainers at a base of the retainers.

32. The mirror subassembly defined in claim 27, wherein the retainers define flexible fingers with hooked ends.

33. The mirror subassembly defined in claim 27, wherein the retainers are uniformly spaced apart in a circumferential direction.

34. The mirror subassembly defined in claim 27, wherein the mirror subassembly includes a rear glass element that is 1.6-mm or less in thickness.

35. The mirror subassembly defined in claim 27, wherein the mirror subassembly includes a front glass element that is 1.6-mm or less in thickness.

36. The mirror subassembly defined in claim 27, wherein the at least one glass element includes a front glass element and a rear glass element, at least one of which is 1.1-mm or less in thickness.

37. The mirror subassembly defined in claim 36, wherein the rear glass element is adhered to the panel-shaped carrier.

38. A mirror subassembly for use in a rearview mirror assembly having a housing and a power angle adjustment device attached to the housing and including an angularly adjustable mount, said mirror subassembly comprising:

a mirror subassembly including at least one glass element, and further including a panel-shaped carrier with a front surface shaped to uniformly support the glass element, the panel-shaped carrier including a plurality of resilient retainers arranged in a circle and extending rearwardly from the panel-shaped carrier and engaging the adjustable mount, the retainers and adjustable mount being configured to positively engage for secure retention but also configured to provide an insertion attachment force of less than 50 pounds force (222 N) during assembly of the panel-shaped carrier to the power pack.

39. The mirror subassembly defined in claim 38, including a resilient ring on the carrier inside of the retainers that abuts the adjustment device and is compressed between the adjustment device and the carrier upon assembly.

40. The mirror subassembly defined in claim 38, wherein the panel-shaped carrier includes continuous rings of material radially inside and outside of the retainers to distribute the insertion attachment force uniformly over an extended area of the mirror subassembly.

41. The mirror subassembly defined in claim 38, wherein the retainers have inclined surfaces configured to provide low friction.

42. The mirror subassembly defined in claim 41, wherein the inclined surfaces are smooth and formed on a polished die surface.

43. The mirror subassembly defined in claim 38, including a foam positioned between the adjustable mount and the carrier, and wherein the retainers grippingly engage the adjustable mount while compressing the foam.

44. A mirror subassembly for use in a rearview mirror assembly having a housing including an arm adapting the housing for attachment to a vehicle in a position outside of the vehicle and a power pack attached to the housing and including an angularly adjustable mount, said mirror subassembly comprising:

a mirror;

a carrier for the mirror, the carrier including a panel-like surface supporting the mirror and including retainers adapted for engaging the adjustable mount, the carrier including a plurality of apertures inboard of a perimeter of the carrier but outboard of a perimeter of the mirror; and

a bezel with a plurality of resilient hooks that extend past the perimeter of the mirror and into the plurality of apertures.

45. A mirror assembly comprising:

a mirror component including first electrical conductors operably connected to the mirror component;

an electrically-operated second component associated with the mirror component and that includes second electrical conductors operably connected to the electrically-operated second component; and

a common connector, said first and second electrical conductors operably connected to said common connector;

wherein said common connector is configured for engaging and electrically connecting to a main connector of a primary wire bundle, which supplies power to the mirror component and to the electrically-operated second component.

46. The mirror assembly defined in claim 45, wherein the electrically-operated second component is a turn signal device adapted to generate a turn signal.

47. A mirror assembly comprising:

a mirror component including first electrical conductors operably connected to the mirror component;

an electrically-operated second component associated with the mirror component and that includes a second electrical conductor operably connected to the electrically-operated second component; and

an electrically-operated third component associated with the mirror component and that includes second electrical conductors operably connected to the electrically-operated second component; and

a common connector, wherein at least two of said first, second, and third electrical conductors are operably connected to said common connector;

wherein said common connector is configured for engaging and electrically connecting to a main connector of a primary wire bundle, which supplies power to at least two of the mirror component, the electrically-operated second component, and the electrically-operated third component.