EXTERIOR MIRROR ASSEMBLY WITH BLIND ZONE INDICATOR

• US 20170092134A1
• Filed: 09/28/2016
• Published: 03/30/2017
• Est. Priority Date: 09/28/2015
• Status: Active Grant

• Current Assignee: Magna Mirrors of America Incorporated (Magna International Incorporated)
• Original Assignee: Magna Mirrors of America Incorporated (Magna International Incorporated)
• Inventors: Kendall, Craig, Shooks, Jeremy R.
• Granted Patent: US 9,659,498 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60R 1/006 Side-view mirrors, e.g. V-shaped mirrors located at the front or rear part of the vehicle combined with rear-view mirrors B60R1/08; side-view periscopes B60R1/10
• CPC Class Codes: B60R 1/06 mounted on vehicle exterior 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 1/1207 with lamps; with turn indicators
• CPC Class Codes: B60R 2001/1215 with information displays
• CPC Class Codes: G08G 1/167 Driving aids for lane monitoring, lane changing, e.g. blind spot detection

Abstract

A mirror reflective element sub-assembly for a vehicular exterior rearview mirror assembly includes a mirror reflective element, a mirror back plate, and a blind zone indication module. The module includes a first portion disposed at an aperture through the back plate and an internal structure that has reflective surfaces and at least one aperture. A circuit board is disposed at a second portion of the housing such that at least one light emitting diode is disposed at a respective aperture of the internal structure. The reflective surfaces are configured so that light emitted by the light emitting diode is generally directed towards the side of the vehicle. The circuit board is disposed at the second portion such that electrically conductive terminals of the circuit board are disposed in a connector portion that is configured to connect to a connector of a wire harness of the exterior rearview mirror assembly.

Claims

1. A mirror reflective element sub-assembly suitable for use for an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

a mirror reflective element;

a mirror back plate attached at the rear of said mirror reflective element, wherein said mirror back plate is formed in a plastic injection molding operation, and wherein an aperture is formed through said mirror back plate;

a blind zone indication module having a light source that is electrically activatable to emit light, wherein said blind zone indication module is disposed at said aperture formed through said mirror back plate, and wherein said light source is electrically activatable to emit light through said mirror reflective element;

wherein said blind zone indication module comprises a plastic housing formed in a plastic injection molding operation;

wherein said housing comprises a first portion and a second portion, with an internal structure formed between said first portion and said second portion, and wherein said housing comprises a connector portion that extends laterally from said second portion;

wherein said internal structure, said first portion, said second portion and said connector portion are integrally molded in the plastic injection molding operation that molds said housing;

wherein said first portion of said housing is disposed at said aperture formed through said mirror back plate;

wherein, with said first portion of said housing disposed at said aperture formed through said mirror back plate, said connector portion of said housing extends parallel to said mirror reflective element;

wherein said blind zone indication module comprises a light source, and wherein said light source comprises at least one light emitting diode disposed at a circuit board of said blind zone indication module;

wherein said circuit board comprises circuitry and electrically conductive terminals electrically connected to said circuitry, and wherein said circuitry includes said at least one light emitting diode, and wherein said electrically conductive terminals extend laterally from said circuit board;

wherein said circuit board is disposed at said second portion of said housing;

wherein said internal structure comprises reflective surfaces and at least one aperture;

wherein said circuit board is disposed at said second portion of said housing such that said at least one light emitting diode is disposed at said at least one aperture of said internal structure, and wherein said reflective surfaces of said internal structure are configured so that, with the exterior rearview mirror assembly attached at a side of a vehicle, light emitted by said at least one light emitting diode is generally directed towards the side of the vehicle at which the exterior rearview mirror assembly is attached;

wherein said circuit board is disposed at said second portion of said housing such that said electrically conductive terminals extend into said connector portion of said housing; and

wherein said connector portion, with said electrically conductive terminals therein, is configured to connect to a connector of a wire harness of the exterior rearview mirror assembly to electrically connect the wire harness to circuitry of said circuit board.

2. The mirror reflective element sub-assembly of claim 1, wherein said first portion of said housing comprises an attaching surface configured to attach said housing at said mirror reflective element, and wherein said attaching surface circumscribes said internal structure.

3. The mirror reflective element sub-assembly of claim 2, wherein a surface of said connector portion of said housing forms part of said attaching surface.

4. The mirror reflective element sub-assembly of claim 3, wherein said aperture formed through said mirror back plate is configured to receive said first portion of said housing with said connector portion.

5. The mirror reflective element sub-assembly of claim 1, wherein said mirror back plate comprises structure at least partially circumscribing said aperture formed through said mirror back plate, and wherein said housing is at least partially received in said structure of said mirror back plate, and wherein an outer end of said connector portion of said housing is disposed at an opening in said structure of said mirror back plate to facilitate connection of said connector portion with the connector of the wire harness of the exterior rearview mirror assembly to electrically connect the wire harness to circuitry of said circuit board.

6. The mirror reflective element sub-assembly of claim 1, wherein said circuit board is generally parallel to said mirror reflective element.

7. The mirror reflective element sub-assembly of claim 1, wherein said reflective surfaces comprise diffusely light reflecting inner surfaces for reflecting light incident thereon to enhance the intensity of light that exits said blind zone indication module.

8. The mirror reflective element sub-assembly of claim 1, wherein said light source comprises a plurality of light emitting diodes and wherein said internal structure comprises a plurality of apertures.

9. The mirror reflective element sub-assembly of claim 1, wherein said light source comprises three triangularly arranged light emitting diodes and wherein said internal structure comprises three triangularly arranged apertures.

10. The mirror reflective element sub-assembly of claim 1, wherein a pressure sensitive adhesive tape is disposed at an attaching surface of said first portion of said housing to attach said attaching surface at said mirror reflective element.

11. The mirror reflective element sub-assembly of claim 10, wherein said pressure sensitive adhesive tape is configured to adhesively attach at said attaching surface of said housing, and wherein said pressure sensitive adhesive tape comprises an aperture therethrough that generally corresponds to the shape of an opening at said attaching surface of said housing.

12. The mirror reflective element sub-assembly of claim 11, wherein said aperture of said pressure sensitive adhesive tape comprises a generally triangular-shaped aperture.

13. The mirror reflective element sub-assembly of claim 11, comprising a diffuser element disposed at said first portion of said housing.

14. The mirror reflective element sub-assembly of claim 10, wherein said attaching surface circumscribes said internal structure, and wherein said pressure sensitive adhesive tape is formed to correspond to the shape of said attaching surface.

15. The mirror reflective element sub-assembly of claim 14, wherein a surface of said connector portion of said housing forms part of said attaching surface.

16. The mirror reflective element sub-assembly of claim 1, comprising a heater pad disposed between said mirror back plate and said mirror reflective element, wherein said heater pad has an aperture formed therethrough that at least partially corresponds with said aperture formed through said mirror back plate.

17. The mirror reflective element sub-assembly of claim 1, wherein said circuitry comprises at least one resistor.

18. A mirror reflective element sub-assembly suitable for use for an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

a mirror reflective element;

a mirror back plate attached at the rear of said mirror reflective element, wherein said mirror back plate is formed in a plastic injection molding operation, and wherein an aperture is formed through said mirror back plate;

a blind zone indication module having a light source that is electrically activatable to emit light, wherein said blind zone indication module is disposed at said aperture formed through said mirror back plate, and wherein said light source is electrically activatable to emit light through said mirror reflective element;

wherein said blind zone indication module comprises a plastic housing formed in a plastic injection molding operation;

wherein said housing comprises a first portion and a second portion, with an internal structure formed between said first portion and said second portion, and wherein said housing comprises a connector portion that extends laterally from said second portion;

wherein said internal structure, said first portion, said second portion and said connector portion are integrally molded in the plastic injection molding operation that molds said housing;

wherein said first portion of said housing comprises an attaching surface and wherein a pressure sensitive adhesive tape is disposed at said attaching surface of said first portion of said housing;

a heater pad disposed between said mirror back plate and said mirror reflective element, wherein said heater pad has an aperture formed therethrough that at least partially corresponds with said aperture formed through said mirror back plate;

wherein said pressure sensitive adhesive tape attaches said attaching surface of said first portion of said housing at one of (i) a rear surface of said heater pad and (ii) a rear surface of said mirror reflective element;

wherein, with said attaching surface of said first portion of said housing attached at said one of (i) a rear surface of said heater pad and (ii) a rear surface of said mirror reflective element, said connector portion of said housing extends parallel to said mirror reflective element;

wherein said blind zone indication module comprises a light source, and wherein said light source comprises at least one light emitting diode disposed at a circuit board of said blind zone indication module;

wherein said circuit board comprises circuitry and electrically conductive terminals electrically connected to said circuitry, and wherein said circuitry includes said at least one light emitting diode, and wherein said electrically conductive terminals extend laterally from said circuit board;

wherein said circuit board is disposed at said second portion of said housing;

wherein said internal structure comprises reflective surfaces and at least one aperture;

wherein said circuit board is disposed at said second portion of said housing such that said at least one light emitting diode is disposed at said at least one aperture of said internal structure, and wherein said reflective surfaces of said internal structure are configured so that, with the exterior rearview mirror assembly attached at a side of a vehicle, light emitted by said at least one light emitting diode is generally directed towards the side of the vehicle at which the exterior rearview mirror assembly is attached;

wherein said circuit board is disposed at said second portion of said housing such that said electrically conductive terminals extend into said connector portion of said housing; and

wherein said connector portion, with said electrically conductive terminals therein, is configured to connect to a connector of a wire harness of the exterior rearview mirror assembly to electrically connect the wire harness to circuitry of said circuit board.

19. The mirror reflective element sub-assembly of claim 18, wherein said pressure sensitive adhesive tape attaches said attaching surface of said first portion of said housing at a rear surface of said heater pad, and wherein said aperture formed through said heater pad corresponds with an aperture formed through said pressure sensitive adhesive tape.

20. The mirror reflective element sub-assembly of claim 18, wherein said pressure sensitive adhesive tape attaches said attaching surface of said first portion of said housing at a rear surface of said mirror reflective element, and wherein said aperture formed through said heater pad corresponds with said aperture formed through said mirror back plate.

21. The mirror reflective element sub-assembly of claim 18, wherein said attaching surface circumscribes said internal structure.

22. The mirror reflective element sub-assembly of claim 18, wherein a surface of said connector portion of said housing forms part of said attaching surface.

23. The mirror reflective element sub-assembly of claim 18, wherein said mirror back plate comprises structure at least partially circumscribing said aperture formed through said mirror back plate, and wherein said housing is at least partially received in said structure of said mirror back plate, and wherein an outer end of said connector portion of said housing is disposed at an opening in said structure of said mirror back plate to facilitate connection of said connector portion with the connector of the wire harness of the exterior rearview mirror assembly to electrically connect the wire harness to circuitry of said circuit board.

24. The mirror reflective element sub-assembly of claim 18, wherein said light source comprises a plurality of light emitting diodes and wherein said internal structure comprises a plurality of apertures.

25. The mirror reflective element sub-assembly of claim 18, wherein said light source comprises three triangularly arranged light emitting diodes and wherein said internal structure comprises three triangularly arranged apertures.

26. The mirror reflective element sub-assembly of claim 18, wherein said pressure sensitive adhesive tape is configured to adhesively attach at said attaching surface of said housing and wherein an aperture of said pressure sensitive adhesive tape generally corresponds to the shape of an opening at said attaching surface of said housing.

27. The mirror reflective element sub-assembly of claim 26, wherein a surface of said connector portion of said housing forms part of said attaching surface.

28. A mirror reflective element sub-assembly suitable for use for an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

a mirror reflective element;

a mirror back plate attached at the rear of said mirror reflective element, wherein said mirror back plate is formed in a plastic injection molding operation, and wherein an aperture is formed through said mirror back plate, and wherein said mirror back plate comprises structure at least partially circumscribing said aperture formed through said mirror back plate;

a blind zone indication module having a light source that is electrically activatable to emit light, wherein said blind zone indication module is disposed at said aperture formed through said mirror back plate, and wherein said light source is electrically activatable to emit light through said mirror reflective element;

wherein said blind zone indication module comprises a plastic housing formed in a plastic injection molding operation;

wherein said housing comprises a first portion and a second portion, with an internal structure formed between said first portion and said second portion, and wherein said housing comprises a connector portion that extends laterally from said second portion;

wherein said internal structure, said first portion, said second portion and said connector portion are integrally molded in the plastic injection molding operation that molds said housing;

a heater pad disposed between said mirror back plate and said mirror reflective element, wherein said heater pad has an aperture formed therethrough that at least partially corresponds with said aperture formed through said mirror back plate;

wherein said first portion of said housing is disposed at said aperture formed through said mirror back plate and is attached at one of (i) a rear surface of said heater pad and (ii) a rear surface of said mirror reflective element;

wherein, with said first portion of said housing disposed at said aperture formed through said mirror back plate and attached at said one of (i) a rear surface of said heater pad and (ii) a rear surface of said mirror reflective element, said connector portion of said housing extends parallel to said mirror reflective element;

wherein said blind zone indication module comprises a light source, and wherein said light source comprises at least one light emitting diode disposed at a circuit board of said blind zone indication module;

wherein said circuit board comprises circuitry and electrically conductive terminals electrically connected to said circuitry, and wherein said circuitry includes said at least one light emitting diode, and wherein said electrically conductive terminals extend laterally from said circuit board;

wherein said circuit board is disposed at said second portion of said housing;

wherein said internal structure comprises reflective surfaces and at least one aperture;

wherein said circuit board is disposed at said second portion of said housing such that said at least one light emitting diode is disposed at said at least one aperture of said internal structure, and wherein said reflective surfaces of said internal structure are configured so that, with the exterior rearview mirror assembly attached at a side of a vehicle, light emitted by said at least one light emitting diode is generally directed towards the side of the vehicle at which the exterior rearview mirror assembly is attached;

wherein said circuit board is disposed at said second portion of said housing such that said electrically conductive terminals extend into said connector portion of said housing;

wherein said connector portion, with said electrically conductive terminals therein, is configured to connect to a connector of a wire harness of the exterior rearview mirror assembly to electrically connect the wire harness to circuitry of said circuit board; and

wherein said housing is at least partially received in said structure of said mirror back plate, and wherein an outer end of said connector portion of said housing is disposed at an opening in said structure of said mirror back plate to facilitate connection of said connector portion with the connector of the wire harness of the exterior rearview mirror assembly to electrically connect the wire harness to circuitry of said circuit board.

29. The mirror reflective element sub-assembly of claim 28, wherein said first portion of said housing comprises an attaching surface that is attached at said one of (i) a rear surface of said heater pad and (ii) a rear surface of said mirror reflective element, and wherein said attaching surface circumscribes said internal structure.

30. The mirror reflective element sub-assembly of claim 29, wherein a surface of said connector portion of said housing forms part of said attaching surface.

31. The mirror reflective element sub-assembly of claim 28, wherein said attaching surface of said first portion of said housing is attached at a rear surface of said heater pad, and wherein said aperture formed through said heater pad corresponds with an opening at said attaching surface.

32. The mirror reflective element sub-assembly of claim 28, wherein said attaching surface of said first portion of said housing is attached at a rear surface of said mirror reflective element, and wherein said aperture formed through said heater pad corresponds with said aperture formed through said mirror back plate.