Mirror assembly

• US 8,079,722 B2
• Filed: 12/28/2007
• Issued: 12/20/2011
• Est. Priority Date: 12/31/2006
• Status: Expired due to Fees

• Current Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Original Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Inventors: Thiele, Steven
• Primary Examiner(s): Doak, Jennifer L.
• Application Number:
  US11/965,909
• Publication Number:
  US 20090116131A1
• Time in Patent Office: 1,453 Days
• Field of Search: None
• US Class Current: 359/883
• CPC Class Codes: B29C 45/16 Making multilayered or multicoloured articles B29C45/0062 takes precedence; feeding colouring materials into the injection unit B29C45/1816
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2011/0058 Mirrors
• CPC Class Codes: Y10S 359/90 Methods

Abstract

A mirror assembly in one embodiment may include a first conductive member that is substantially transparent, a second conductive member that comprises a reflective portion, a third conductive member that is operatively connected to the first conductive member and the second conductive member, a front portion that is substantially transparent and that is formed by injecting a first thermoplastic material into a mold on a first side of the first conductive member, an inner portion that is formed by injecting a second thermoplastic material into the mold on a second side of the second conductive member, and a back portion that is substantially opaque and that is formed by injecting a third thermoplastic material into the mold on the second side of the second conductive member. The front portion and the back portion together may substantially encompass a first perimeter of the first conductive member and a second perimeter of the second conductive member.

Claims

1. A device comprising:

a mirror assembly comprising;

a first conductive member having a first side, a second side, a first perimeter, and a first busbar, wherein the first conductive member is substantially transparent;

a second conductive member having a first side, a second side, a second perimeter, and a second busbar, wherein the second conductive member comprises a reflective portion;

a third conductive member that is operatively connected to the first conductive member and the second conductive member and that is substantially transparent;

a front portion that is substantially transparent and that is formed by injecting a first thermoplastic material into a mold on the first side of the first conductive member;

an inner portion that is substantially transparent and that is formed by injecting a second thermoplastic material into the mold on the second side of the second conductive member; and

a back portion that is substantially opaque and that is formed by injecting a third thermoplastic material into the mold on the second side of the second conductive member, wherein the front portion and the back portion together substantially encompass the first perimeter and the second perimeter;

wherein the first thermoplastic material is a first polycarbonate material;

wherein the second thermoplastic material is a second polycarbonate material; and

wherein the third thermoplastic material is a third polycarbonate material.

2. The device of claim 1 further comprising:

a scratch resistant material covering at least a portion of the front portion.

3. The device of claim 1, wherein:

the back portion is formed within the mold to have an electrical connection that is operatively connected to the first and second busbars.

4. The device of claim 1, wherein:

the back portion substantially encompasses the first perimeter of the first conductive member and the second perimeter of the second conductive member and seals the assembly.

5. The device of claim 1, wherein:

the front portion substantially encompasses the first perimeter of the first conductive member and the second perimeter of the second conductive member and seals the assembly.

6. The device of claim 1, wherein:

the back portion is formed within the mold to have a first attachment portion for use in attaching the device to a vehicle.

7. A vehicle comprising:

a vehicle frame;

an engine supported to the vehicle frame;

at least one ground engaging wheel supported to the frame and operatively connected to the engine to provide locomotion to the vehicle;

a vehicle body supported to the frame and defining a passenger compartment; and

,

a mirror assembly supported to the vehicle, the mirror assembly comprising;

a first conductive member having a first side, a second side, a first perimeter, and a first busbar, wherein the first conductive member is substantially transparent;

a second conductive member having a first side, a second side, a second perimeter, and a second busbar, wherein the second conductive member comprises a reflective portion;

a third conductive member that is operatively connected to the first conductive member and the second conductive member and that is substantially transparent;

a front portion that is substantially transparent and that is formed by injecting a first thermoplastic material into a mold on the first side of the first conductive member;

an inner portion that is substantially transparent and that is formed by injecting a second thermoplastic material into the mold on the second side of the second conductive member; and

a back portion that is substantially opaque and that is formed by injecting a third thermoplastic material into the mold on the second side of the second conductive member, wherein the front portion and the back portion together substantially encompass the first perimeter and the second perimeter;

wherein the first thermoplastic material is a first polycarbonate material;

wherein the second thermoplastic material is a second polycarbonate material; and

wherein the third thermoplastic material is a third polycarbonate material.

8. The vehicle of claim 7 wherein the mirror assembly further comprises:

a scratch resistant material covering at least a portion of the front portion.

9. The vehicle of claim 7, wherein:

the back portion is formed within the mold to have an electrical connection that is operatively connected to the first and second busbars.

10. The vehicle of claim 7, wherein:

the back portion is formed within the mold to have a first attachment portion for use in attaching the device to a vehicle.

11. The vehicle of claim 7, wherein:

the back portion is formed within the mold to have a second attachment portion for use in attaching the mirror assembly to the vehicle.

12. The vehicle of claim 7, wherein:

the first attachment portion is used to attach the mirror assembly to the exterior of the vehicle.

13. The vehicle of claim 7, wherein:

the first attachment portion is used to attach the mirror assembly to the interior of the vehicle.

14. A method of forming a minor assembly comprising the steps of:

(a) inserting a first conductive member into a mold, wherein the first conductive member comprises a first busbar and a first perimeter, wherein the first conductive member is substantially transparent when the minor assembly is used;

(b) inserting a first thermoplastic material into the mold to form a front portion on a first side of the first conductive member, wherein the front portion is substantially transparent when the mirror assembly is used;

(c) inserting a second conductive member into the mold, wherein the second conductive member comprises a second busbar, a second perimeter, and a reflective portion when the mirror assembly is used;

(d) inserting a second thermoplastic material into the mold to form an inner portion on a second side of the second conductive member, wherein the inner portion is substantially transparent when the mirror assembly is used;

(e) inserting a third conductive member into the mold wherein the third conductive member is operatively connected to the first conductive member and the second conductive member and is substantially transparent; and

(f) inserting a third thermoplastic material into the mold on the second side of the second conductive member to form a back portion, wherein the back portion is substantially opaque when the mirror assembly is used, wherein the front portion and the back portion together substantially encompass the first perimeter and the second perimeter;

step (b) comprises the step of;

injecting a first polycarbonate material into the mold;

step (d) comprises the step of;

injecting a second polycarbonate material into the mold; and

,

step (f) comprises the step of;

injecting a third polycarbonate material into the mold.

15. The method of claim 14 further comprising the steps of:

applying a scratch resistant material to the front portion.

16. The method of claim 14 wherein:

step (f) comprises the step of;

forming a back portion within the mold to have an electrical connection that is operatively connected to the first and second busbars.

17. The method of claim 14, wherein:

step (f) comprises the step of;

sealing the assembly.