Method for forming constant radius convex mirror assembly

• US 6,282,771 B2
• Filed: 12/29/2000
• Issued: 09/04/2001
• Est. Priority Date: 11/23/1999
• Status: Expired due to Term

• Current Assignee: Rosco Incorporated
• Original Assignee: Rosco Incorporated
• Inventors: Englander, Benjamin
• Primary Examiner(s): Hughes, S. Thomas
• Assistant Examiner(s): Blount, Steven
• Application Number:
  US09/750,938
• Publication Number:
  US 20010001342A1
• Time in Patent Office: 249 Days
• Field of Search: 294/28, 294/50
• US Class Current: 29/450
• CPC Class Codes: B60R 1/082 using a single wide field mirror or an association of rigidly connected mirrors
• CPC Class Codes: G02B 5/10 with curved faces
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/4987 Elastic joining of parts

Abstract

A safety mirror lens assembly includes a mirror unit with a mirror lens that has a three-dimensional convex/ellipsoid reflective surface which terminates in an oval or round or other shape peripheral edge. The reflective surface is such that a notional line traced to coincides with the major axis has a first constant radius of curvature and a second notional line traced to coincide with the minor axis has a second constant radius of curvature. The first radius of curvature is substantially greater than the second radius of curvature. The mirror lens is usable for a cross-over mirror for a vehicle, for example, a school bus.

Claims

1. A method of fabricating a mirror unit, comprising the steps of:

producing by injection molding, a mirror lens having a reflective outer surface and a rear surface, the mirror lens comprising a mirror lens body which terminates in an oval shape peripheral edge that surrounds the reflective surface, the mirror lens body being a substantially three-dimensional, convex body having a major axis of a first length and a minor axis which intersects the major axis and has a second length, the major axis and the minor axis being defined in a plane that contains the oval shape peripheral edge, the outer mirror surface having a first constant radius of curvature along a first line thereof which coincides with the major axis and having a second, constant radius of curvature on the outer surface thereof along a second line which coincides with the minor axis of the lens, said first constant radius of curvature being substantially larger than said second constant radius of curvature; and

providing a mirror back and coupling the mirror back to the mirror lens body; and

providing a coupling structure and attaching the coupling structure to the mirror back.

2. The method of claim 1, including attaching the mirror back to the lens by means of a gasket made of resilient synthetic material.

3. The method of claim 1, in which the mirror lens body comprises a plurality of notional trace lines each of which has said second, constant radius of curvature, wherein each of said plurality of trace lines lies in a plane which also contains said vertical axis.

4. The method of claim 3, in which the mirror lens body includes a second plurality of notional trace lines, each one of said second plurality of notional trace lines having a respective, constant radius of curvature.

5. A method of fabricating a mirror unit comprising the step of:

producing by injection molding, a mirror lens having a reflective outer surface and a rear surface, the mirror lens comprising a mirror lens body which terminates in a circular peripheral edge that surrounds the reflective surface, the mirror lens body being a substantially three-dimensional, spherical body, the outer mirror surface having a constant radius of curvature along any trace line thereof which begins at a first point on the peripheral edge, terminates on a second point on the peripheral edge and lies in a plane that also contains a vertical axis around which the spherical mirror lens body is symmetrically arranged, each trace line having the same constant radius of curvature; and

attaching to the mirror lens a mirror assembly structure including a mirror back adjacent the continuous peripheral edge of the mirror lens;

a fastening structure for fastening the mirror back to the mirror lens; and

a coupling structure attached to the mirror back, the coupling structure including hardware for engaging a mirror pole which serves to attach the mirror unit to a vehicle body in a manner which allows the orientation of the mirror lens to be adjusted.

6. A method of fabricating a mirror unit comprising the steps of:

producing by injection molding, a mirror lens having a reflective outer surface and a rear surface, the mirror lens comprising a mirror lens body which terminates in a peripheral edge that surrounds the reflective surface, the mirror lens body having a substantially three-dimensional, spherical body, the outer mirror surface having a constant radius of curvature along any straight, unidirectional trace line thereof, which trace line begins at a first point on the peripheral edge and terminates on a opposed second points on the peripheral edge; and

attaching to the mirror lens a mirror assembly structure including a mirror back adjacent the peripheral edge of the mirror lens;

a fastening structure for fastening the mirror back to the mirror lens; and

a coupling structure attached to the mirror back, the coupling structure including hardware for engaging a mirror pole which serves to attach the mirror unit to a vehicle body in a manner which allows the orientation of the mirror lens to be adjusted.