Outside sideview mirror assembly with reduced wind noise
First Claim
1. A method of forming a composite shell, the shell forming a body for a vehicular sideview exterior mirror assembly, the body being adapted for mounting to a vehicle and defining a cavity and an opening for facing rearward of a vehicle when the body is mounted to a vehicle, and supporting a reflective element positioned in the opening for rearview viewing of the vehicle, and the body having a forward facing exterior side when mounted to a vehicle, said method comprising:
- providing a mold assembly with a mold cavity, said mold cavity including a discontinuity having an edge definition for forming a discontinuity in the composite shell and having a first molding surface and a second molding surface, the first molding surface for forming an inner surface of the composite shell, and the second molding surface for forming the outer surface of the shell for forming the forward facing exterior side of the body;
positioning a decorative film substrate in said mold cavity on said second molding surface, wherein the decorative film substrate extends over the discontinuity;
injecting a polymer resin in said mold cavity over said decorative film substrate; and
conforming said film substrate and said polymer resin to said mold cavity whereby said film substrate and said polymer resin conform to the mold cavity and, further, substantially conform to the edge definition of the discontinuity to thereby form the composite shell wherein at least a portion of the forward facing exterior side includes the decorative film conformed therewith, with the decorative film and the polymer resin substantially conforming to each other to reduce the wind noise of the sideview exterior mirror assembly when the body is mounted to a vehicle.
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Accused Products
Abstract
A method of forming a composite shell member for a vehicular sideview exterior mirror assembly includes providing a decorative film substrate and a polymer resin. A shell is formed the decorative film substrate and the polymer resin to form the shell member. A discontinuity is formed in the polymer resin, with the film substrate conformed to the polymer resin to generally follow the edge definition of the discontinuity to form a surface discontinuity in an outer surface of the shell member having substantially the same edge definition of the discontinuity of the polymer resin.
13 Citations
26 Claims
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1. A method of forming a composite shell, the shell forming a body for a vehicular sideview exterior mirror assembly, the body being adapted for mounting to a vehicle and defining a cavity and an opening for facing rearward of a vehicle when the body is mounted to a vehicle, and supporting a reflective element positioned in the opening for rearview viewing of the vehicle, and the body having a forward facing exterior side when mounted to a vehicle, said method comprising:
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providing a mold assembly with a mold cavity, said mold cavity including a discontinuity having an edge definition for forming a discontinuity in the composite shell and having a first molding surface and a second molding surface, the first molding surface for forming an inner surface of the composite shell, and the second molding surface for forming the outer surface of the shell for forming the forward facing exterior side of the body; positioning a decorative film substrate in said mold cavity on said second molding surface, wherein the decorative film substrate extends over the discontinuity; injecting a polymer resin in said mold cavity over said decorative film substrate; and conforming said film substrate and said polymer resin to said mold cavity whereby said film substrate and said polymer resin conform to the mold cavity and, further, substantially conform to the edge definition of the discontinuity to thereby form the composite shell wherein at least a portion of the forward facing exterior side includes the decorative film conformed therewith, with the decorative film and the polymer resin substantially conforming to each other to reduce the wind noise of the sideview exterior mirror assembly when the body is mounted to a vehicle. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of forming a composite shell, the composite shell forming a body for a vehicular sideview exterior mirror assembly, the body being adapted for mounting to a vehicle and defining a cavity and an opening for facing rearward of a vehicle when the body is mounted to a vehicle , and supporting a reflective element positioned in the opening for rearview viewing of the vehicle, and the body having a forward facing exterior side when mounted to a vehicle, said method comprising:
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providing a decorative film substrate; providing a polymer resin; forming the shell from the decorative film substrate and the polymer resin; and forming a discontinuity having an edge definition in the polymer resin; and conforming the film substrate to the polymer resin to generally follow the edge definition of the discontinuity to form a surface discontinuity in an outer surface of the shell having substantially the same edge definition of the discontinuity of the polymer resin, wherein at least a portion of the forward facing exterior side includes the decorative film substrate conformed thereto, the decorative film substrate extends over the surface discontinuity and substantially conforms thereto to reduce the wind noise of the sideview exterior mirror assembly when the body is mounted to a vehicle. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20)
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21. A method of forming a composite shell, the composite shell forming a body for a vehicular sideview exterior mirror assembly, the body being adapted for mounting to a vehicle and defining a cavity and an opening for facing rearward of a vehicle when the body is mounted to a vehicle, and supporting a reflective element positioned in the opening for rearview viewing of the vehicle, and the body having a forward facing exterior side when mounted to a vehicle, said method comprising:
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providing a decorative film substrate; providing a polymer resin; forming the shell from the decorative film substrate and a polymer resin, the decorative film substrate forming an outer surface of the shell and conforming to at least a portion of the forward facing exterior side; and forming a discontinuity in the outer surface of the shell, wherein the decorative film substrate extends over the discontinuity and substantially conforms thereo to reduce the wind noise of the sideview exterior mirror assembly when the body is mounted to a vehicle. - View Dependent Claims (22, 23, 24, 25, 26)
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Specification