Rearview assembly having an integral crush zone

• US 20050270621A1
• Filed: 11/10/2004
• Published: 12/08/2005
• Est. Priority Date: 06/08/2004
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Bauer, Frederick T., Watson, Alan R., Turnbull, Robert R., Rumsey, Wayne J., Bostwick, Daniel J.
• Granted Patent: US 7,196,836 B2
• Time in Patent Office: Days
• US Class Current: 359/265
• 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 1/12 Mirror assemblies combined with other articles, e.g. clocks
• CPC Class Codes: H05K 1/0274 Optical details, e.g. printed circuits comprising integral optical means H05K1/0269 takes precedence; coupling light guides with opto-electronic components G02B6/42
• CPC Class Codes: H05K 1/0306 Inorganic insulating substrates, e.g. ceramic, glass
• CPC Class Codes: H05K 2201/0108 Transparent
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10651 Component having two leads, e.g. resistor, capacitor
• CPC Class Codes: H05K 2201/2036 Permanent spacer or stand-off in a printed circuit or printed circuit assembly pattern for applying drops or paste H05K2203/0545
• CPC Class Codes: H05K 2201/2054 Light-reflecting surface, e.g. conductors, substrates, coatings, dielectrics
• CPC Class Codes: H05K 3/321 by conductive adhesives

Abstract

A rearview assembly comprising a rearview element, a rearview element support assembly supporting the rearview element and a mount adjacent the housing. The mount is configured to connect the rearview assembly to a windshield. At least one of the rearview element support assembly and the mount comprises a crush bracket having at least two legs adapted to be compressed as a force strikes a front of the rearview element. The crush bracket can include at least one tab contacting a heat emitting component and/or an electrically conductive component of a circuit to provide a heat sink for the heat emitting component or a ground for the electrically conductive component, respectively.

Claims

1. A rearview assembly comprising:

a rearview element having a front surface and a rear surface;

a crush bracket connected to the rear surface of the rearview element, the crush bracket including a support panel directly connected to the rear surface of the rearview element and at least two legs extending from the support panel in a direction opposite to the rearview element; and

a mount interconnected to the at least two legs of the crush bracket;

the at least two legs being configured to collapse in a direction between the rear surface of the rearview element and the mount as a striking force strikes the front surface of the rearview element.

2. The rearview assembly of claim 1, wherein:

the rearview element comprises an electrochromic rearview element assembly including a front glass element and a rear glass element, with electrochromic material located between the front glass element and the rear glass element;

the front surface is on the front glass element; and

the rear surface is on the rear glass element.

3. The rearview assembly of claim 1, wherein:

double-sided adhesive foam tape directly connects the support panel of the crush bracket to the rear surface of the rearview element.

4. The rearview assembly of claim 1, wherein:

the rearview element has a portion of a circuit provided directly on the rear surface.

5. The rearview assembly of claim 1, further including:

a printed circuit board connected to the crush bracket.

6. The rearview assembly of claim 1, further including:

an electrical circuit in the rearview element housing, the electrical circuit including a heat emitting component;

wherein the crush bracket includes a portion thereof contacting the heat emitting component to provide a heat sink for the heat emitting component.

7. The rearview assembly of claim 6, wherein:

the portion of the crush bracket comprises resilient fingers resiliently pressed against the heat emitting component.

8. The rearview assembly of claim 6, wherein:

the rearview element has at least a portion of the electrical circuit provided directly on the rear surface thereof; and

the at least a portion of the electrical circuit includes the heat emitting component.

9. The rearview assembly of claim 1, further including:

an electrical circuit in the rearview element housing, the electrical circuit including an electrically conductive component;

wherein the crush bracket includes at least a portion thereof contacting the electrically conductive component to provide a ground for the electrically conductive component.

10. The rearview assembly of claim 9, wherein:

the portion of the crush bracket comprises resilient fingers resiliently pressed against the electrically conductive component.

11. The rearview assembly of claim 9, wherein:

the rearview element has at least a portion of the electrical circuit provided directly on the rear surface thereof; and

the at least a portion of the electrical circuit includes the electrically conductive component.

12. The rearview assembly of claim 1, wherein:

the crush bracket compresses at least 1.0 mm without breaking the rearview element as the front surface of the rearview element is subjected to a force no greater than 400 N (90 pounds) in any direction that is not more than 45°

from a forward longitudinal direction of motion of a vehicle having the rearview assembly connected thereto.

13. The rearview assembly of claim 1, further including:

a housing having the rearview element therein;

wherein the rearview element does not contact the housing.

14. The rearview assembly of claim 1, further including:

a connection plate connected to the at least two legs of the crush bracket and the mount.

15. The rearview assembly of claim 14, wherein:

the mount includes a ball adapted to be received within the connection plate to thereby interconnect the mount to the crush bracket.

16. The rearview assembly of claim 14, further including:

a first pivot ball connected to the connection plate and a sleeve connected to the first pivot ball;

wherein the mount includes a second pivot ball connected to the sleeve to thereby interconnect the mount to the crush bracket.

17. The rearview assembly of claim 14, further including:

a housing having the reflecting element, the crush bracket and the connection plate therein;

the housing being frictionally engaged between the mount and the connection plate.

18. The rearview assembly of claim 17, wherein:

the housing does not abut the rearview element.

19. The rearview assembly of claim 1, wherein:

the at least two legs include connection panels on ends thereof; and

the connection panels move towards the support panel as the at least two legs are collapsed in a direction between the rear surface of the rearview element and the mount.

20. The rearview assembly of claim 1, wherein:

the at least two legs are two legs.

21. The rearview assembly of claim 1, wherein:

the at least two legs are each bowed outwardly.

22. The rearview assembly of claim 1, wherein:

the support panel is split and includes two separate portions.

23. The rearview assembly of claim 1, wherein:

the rearview element has a portion of a circuit provided directly on the rear surface thereof, the circuit including a glare sensor for measuring glare.

24. The rearview assembly of claim 23, wherein:

the rearview element comprises an electrochromic rearview element assembly including a front glass element and a rear glass element, with electrochromic material located between the front glass element and the rear glass element;

the front surface is on the front glass element;

the rear surface is on the rear glass element.

25. The rearview assembly of claim 24, wherein:

the electrochromic rearview element assembly darkens in response to the glare sensed by the glare sensor.

26. A rearview assembly comprising:

a rearview element having a front surface and a rear surface, the rearview element having a portion of a circuit provided directly on the rear surface;

a crush bracket connected to the rear surface of the rearview element, the crush bracket including at least two legs; and

a mount interconnected to the at least two legs of the crush bracket;

the at least two legs being configured to collapse in a direction between the rear surface of the rearview element and the mount as a striking force strikes the front surface of the rearview element.

27. The rearview assembly of claim 26, wherein:

the rearview element comprises an electrochromic rearview element assembly including a front glass element and a rear glass element, with electrochromic material located between the front glass element and the rear glass element;

the front surface is on the front glass element; and

the rear surface is on the rear glass element.

28. The rearview assembly of claim 26, wherein:

double-sided adhesive foam tape directly connects the crush bracket to the rear surface of the rearview element.

29. The rearview assembly of claim 26, wherein:

the circuit includes a heat emitting component; and

the crush bracket includes at least a portion thereof contacting the heat emitting component to provide a heat sink for the heat emitting component.

30. The rearview assembly of claim 29, wherein:

the portion of the crush bracket comprises resilient fingers resiliently pressed against the heat emitting component.

31. The rearview assembly of claim 26, further including:

the circuit includes an electrically conductive component; and

the crush bracket includes at least a portion thereof contacting the electrically conductive component to provide a ground for the electrically conductive component.

32. The rearview assembly of claim 31, wherein:

the portion of the crush bracket comprises resilient fingers resiliently pressed against the electrically conductive component.

33. The rearview assembly of claim 26, wherein:

the crush bracket compresses at least 1.0 mm without breaking the rearview element as the front surface of the rearview element is subjected to a force no greater than 400 N (90 pounds) in any direction that is not more than 45°

from a forward longitudinal direction of motion of a vehicle having the rearview assembly connected thereto.

34. The rearview assembly of claim 26, further including:

a housing having the rearview element therein;

wherein the rearview element does not contact the housing.

35. The rearview assembly of claim 26, further including:

a connection plate connected to the at least two legs of the crush bracket and the mount.

36. The rearview assembly of claim 35, wherein:

the mount includes a ball adapted to be received within the connection plate to thereby interconnect the mount to the crush bracket.

37. The rearview assembly of claim 35, further including:

a first pivot ball connected to the connection plate and a sleeve connected to the first pivot ball;

wherein the mount includes a second pivot ball connected to the sleeve to thereby interconnect the mount to the crush bracket.

38. The rearview assembly of claim 35, further including:

a housing having the reflecting element, the crush bracket and the connection plate therein;

the housing being frictionally engaged between the mount and the connection plate.

39. The rearview assembly of claim 38, wherein:

the housing does not abut the rearview element.

40. The rearview assembly of claim 26, wherein:

the at least two legs include connection panels on ends thereof; and

the connection panels move towards the support panel as the at least two legs are collapsed in a direction between the rear surface of the rearview element and the mount.

41. The rearview assembly of claim 26, wherein:

the at least two legs are two legs.

42. The rearview assembly of claim 26, wherein:

the at least two legs are each bowed outwardly.

43. The rearview assembly of claim 26, wherein:

the crush bracket includes a support panel that is split and includes two separate portions.

44. The rearview assembly of claim 26, wherein:

the rearview element has a portion of a circuit provided directly on the rear surface thereof, the circuit including a glare sensor for measuring glare.

45. The rearview assembly of claim 44, wherein:

the rearview element comprises an electrochromic rearview element assembly including a front glass element and a rear glass element, with electrochromic material located between the front glass element and the rear glass element;

the front surface is on the front glass element;

the rear surface is on the rear glass element.

46. The rearview assembly of claim 45, wherein:

the electrochromic rearview element assembly darkens in response to the glare sensed by the glare sensor.

47. A rearview assembly comprising:

a rearview element having a front surface and a rear surface;

a support plate supporting the rearview element;

a crush bracket connected to the support plate, the crush bracket including a support panel connected to the support plate and at least two legs extending from the support panel; and

a mount interconnected to the at least two legs of the crush bracket;

the at least two legs being configured to collapse in a direction between the rear surface of the rearview element and the mount as a striking force strikes the front surface of the rearview element.

48. The rearview assembly of claim 47, wherein:

the rearview element comprises an electrochromic rearview element assembly including a front glass element and a rear glass element, with electrochromic material located between the front glass element and the rear glass element;

the front surface is on the front glass element; and

the rear surface is on the rear glass element.

49. The rearview assembly of claim 47, wherein:

double-sided adhesive foam tape directly connects the crush bracket to the support plate.

50. The rearview assembly of claim 47, wherein:

the rearview element has a portion of a circuit provided directly on the rear surface.

51. The rearview assembly of claim 47, further including:

a printed circuit board connected to the support plate.

52. The rearview assembly of claim 47, further including:

an electrical circuit in the rearview element housing, the electrical circuit including a heat emitting component;

wherein the crush bracket includes at least a portion thereof contacting the heat emitting component to provide a heat sink for the heat emitting component.

53. The rearview assembly of claim 47, further including:

an electrical circuit in the rearview element housing, the electrical circuit including an electrically conductive component;

wherein the crush bracket includes at least a portion thereof contacting the electrically conductive component to provide a ground for the electrically conductive component.

54. The rearview assembly of claim 47, wherein:

the crush bracket compresses at least 1.0 mm without breaking the rearview element as the front surface of the rearview element is subjected to a force no greater than 400 N (90 pounds) in any direction that is not more than 45°

from a forward longitudinal direction of motion of a vehicle having the rearview assembly connected thereto.

55. The rearview assembly of claim 47, further including:

a connection plate connected to the at least two legs of the crush bracket and the mount.

56. The rearview assembly of claim 55, wherein:

the mount includes a ball adapted to be received within the connection plate to thereby interconnect the mount to the crush bracket.

57. The rearview assembly of claim 55, further including:

a first pivot ball connected to the connection plate and a sleeve connected to the first pivot ball;

wherein the mount includes a second pivot ball connected to the sleeve to thereby interconnect the mount to the crush bracket.

58. The rearview assembly of claim 55, further including:

a housing having the reflecting element, the crush bracket and the connection plate therein;

the housing being frictionally engaged between the mount and the connection plate.

59. The rearview assembly of claim 58, wherein:

the housing does not abut the rearview element.

60. The rearview assembly of claim 47, wherein:

the at least two legs include connection panels on ends thereof; and

the connection panels move towards the support panel as the at least two legs are collapsed in a direction between the rear surface of the rearview element and the mount.

61. The rearview assembly of claim 47, wherein:

the at least two legs are two legs.

62. The rearview assembly of claim 47, wherein:

the at least two legs are each bowed outwardly.

63. The rearview assembly of claim 47, wherein:

the crush bracket includes a support panel that is split and includes two separate portions.

64. The rearview assembly of claim 47, further including:

a circuit board connected to the support plate, the circuit board having an opening therethrough;

wherein the crush bracket extends through the opening.

65. The rearview assembly of claim 64, wherein:

the circuit board includes a glare sensor thereon for measuring glare.

66. The rearview assembly of claim 65, wherein:

the rearview element comprises an electrochromic rearview element assembly including a front glass element and a rear glass element, with electrochromic material located between the front glass element and the rear glass element;

the front surface is on the front glass element;

the rear surface is on the rear glass element.

67. The rearview assembly of claim 66, wherein:

the electrochromic rearview element assembly darkens in response to the glare sensed by the glare sensor.

68. A rearview assembly comprising:

a rearview element;

a rearview element support assembly supporting the rearview element;

a mount being configured to connect the rearview assembly to a windshield;

at least one of the rearview element support assembly and the mount comprising a crush bracket having at least two legs adapted to be compressed as a force strikes a front of the rearview element.

69. The rearview assembly of claim 68, wherein:

the rearview element comprises an electrochromic rearview element assembly including a front glass element and a rear glass element, with electrochromic material located between the front glass element and the rear glass element.

70. The rearview assembly of claim 68, wherein:

the rearview element support assembly comprises the crush bracket, with the crush bracket including a support panel directly connected to a rear surface of the rearview element, and the at least two legs extend from the support panel in a direction opposite the rearview element.

71. The rearview assembly of claim 68, wherein:

double-sided adhesive foam tape directly connects the support panel of the crush bracket to the rear surface of the rearview element.

72. The rearview assembly of claim 68, wherein:

the rearview element has a portion of a circuit provided directly on the rear surface.

73. The rearview assembly of claim 68, further including:

a printed circuit board connected to the crush bracket.

74. The rearview assembly of claim 68, further including:

an electrical circuit in the housing, the electrical circuit including a heat emitting component;

wherein the crush bracket includes at least a portion thereof contacting the heat emitting component to provide a heat sink for the heat emitting component.

75. The rearview assembly of claim 74, wherein:

the rearview element has at least a portion of the electrical circuit provided directly on the rear surface thereof; and

the at least a portion of the electrical circuit includes the heat emitting component.

76. The rearview assembly of claim 68, further including:

an electrical circuit in the rearview element housing, the electrical circuit including an electrically conductive component;

wherein the crush bracket includes at least one tab contacting the electrically conductive component to provide a ground for the electrically conductive component.

77. The rearview assembly of claim 76, wherein:

the rearview element has at least a portion of the electrical circuit provided directly on the rear surface thereof; and

the at least a portion of the electrical circuit includes the electrically conductive component.

78. The rearview assembly of claim 68, wherein:

the crush bracket compresses at least 1.0 mm without breaking the rearview element as the front surface of the rearview element is subjected to a force no greater than 400 N (90 pounds) in any direction that is not more than 45°

from a forward longitudinal direction of motion of a vehicle having the rearview assembly connected thereto.

79. The rearview assembly of claim 68, wherein:

the rearview element does not contact the housing.

80. The rearview assembly of claim 68, further including:

a connection plate connected to the at least two legs of the crush bracket and the mount.

81. The rearview assembly of claim 80, wherein:

the mount includes a ball adapted to be received within the connection plate to thereby interconnect the mount to the crush bracket.

82. The rearview assembly of claim 80, further including:

a first pivot ball connected to the connection plate and a sleeve connected to the first pivot ball;

wherein the mount includes a second pivot ball connected to the sleeve to thereby interconnect the mount to the crush bracket.

83. The rearview assembly of claim 80, further including:

a housing having the reflecting element, the crush bracket and the connection plate therein;

the housing being frictionally engaged between the mount and the connection plate.

84. The rearview assembly of claim 83, wherein:

the housing does not abut the rearview element.

85. The rearview assembly of claim 68, wherein:

the at least two legs include connection panels on ends thereof; and

the connection panels move towards the support panel as the at least two legs are collapsed in a direction between the rear surface of the rearview element and the mount.

86. The rearview assembly of claim 68, wherein:

the at least two legs are two legs.

87. The rearview assembly of claim 68, wherein:

the at least two legs are each bowed outwardly.

88. The rearview assembly of claim 68, wherein:

the crush bracket includes a support panel that is split and includes two separate portions.

89. A rearview assembly comprising:

a rearview element;

a housing having the rearview element therein;

an electrical circuit in the housing, the electrical circuit including a heat emitting component; and

a crush bracket interconnected to the rearview element, the crush bracket including at least a portion thereof contacting the heat emitting component to provide a heat sink for the heat emitting component.

90. The rearview assembly of claim 89, wherein:

the crush bracket is connected to a rear surface of the rearview element; and

the crush bracket includes at least two legs; and

further includes a mount interconnected to the at least two legs of the crush bracket;

wherein the at least two legs are configured to collapse in a direction between the rear surface of the rearview element and the mount as a striking force strikes the front surface of the rearview element.

91. The rearview assembly of claim 90, wherein:

the crush bracket includes at least two legs;

the at least two legs include connection panels on ends thereof; and

the connection panels move towards the support panel as the at least two legs are collapsed in a direction between the rear surface of the rearview element and the mount.

92. A rearview assembly comprising:

a rearview element;

a rearview element housing having the rearview element therein;

an electrical circuit in the rearview element housing, the electrical circuit including an electrically conductive component;

a crush bracket interconnected to the rearview element, the crush bracket including at least a portion thereof contacting the electrically conductive component to provide a ground for the electrically conductive component.

93. The rearview assembly of claim 92, wherein:

the crush bracket is connected to a rear surface of the rearview element; and

the crush bracket includes at least two legs; and

further includes a mount interconnected to the at least two legs of the crush bracket;

wherein the at least two legs are configured to collapse in a direction between the rear surface of the rearview element and the mount as a striking force strikes the front surface of the rearview element.

94. The rearview assembly of claim 93, wherein:

the crush bracket includes at least two legs;

the at least two legs include connection panels on ends thereof; and

the connection panels move towards the support panel as the at least two legs are collapsed in a direction between the rear surface of the rearview element and the mount.

95. A rearview assembly for a vehicle comprising:

a rearview element having a reflective surface;

a rearview element housing having at least a portion of the rearview element therein;

a mount for connecting the rearview element and the rearview element housing to a windshield of the vehicle;

wherein a portion of the rearview assembly non-elastically compresses at least 1.0 mm without breaking the rearview element as the reflective surface of the rearview element is subjected to a force no greater than 400 N (90 pounds) in any direction that is not more than 45°

from a forward longitudinal direction of motion of the vehicle.

96. The rearview assembly of claim 95, wherein:

the rearview element includes a front surface and a rear surface; and

the portion comprises a crush bracket connected to the rear surface of the rearview element, the crush bracket including a support panel directly connected to the rear surface of the rearview element and at least two legs extending from the support panel in a direction opposite the rearview element;

the mount is interconnected to the at least two legs of the crush bracket; and

the at least two legs are configured to collapse in a direction between the rear surface of the rearview element and the mount as a striking force strikes the front surface of the rearview element.

97. The rearview assembly of claim 96, wherein:

the at least two legs include connection panels on ends thereof; and

the connection panels move towards the support panel as the at least two legs are collapsed in a direction between the rear surface of the rearview element and the mount.

98. The rearview assembly of claim 96, wherein:

the at least two legs are two legs.

99. The rearview assembly of claim 96, wherein:

the at least two legs are each bowed outwardly.

100. The rearview assembly of claim 95, wherein:

the rearview element has a front surface and a rear surface;

a support plate supports the rearview element;

the portion comprises a crush bracket connected to the support plate, the crush bracket including a support panel connected to the support plate and at least two legs extending from the support panel;

the mount is interconnected to the at least two legs of the crush bracket; and

the at least two legs are configured to collapse in a direction between the rear surface of the rearview element and the mount as a striking force strikes the front surface of the rearview element.

101. The rearview assembly of claim 95, wherein:

the rearview element comprises an electrochromic rearview element assembly including a front glass element and a rear glass element, with electrochromic material located between the front glass element and the rear glass element.

102. The rearview assembly of claim 95, wherein:

the portion comprises a crush bracket interconnected to the rearview element; and

double-sided adhesive foam tape directly connects the crush bracket to a rear surface of the rearview element.

103. The rearview assembly of claim 95, wherein:

the rearview element has a portion of a circuit provided directly on the rear surface.

104. The rearview assembly of claim 95, further including:

an electrical circuit in the rearview element housing, the electrical circuit including a heat emitting component;

wherein the crush bracket includes a portion thereof contacting the heat emitting component to provide a heat sink for the heat emitting component.

105. The rearview assembly of claim 104, wherein:

the portion of the crush bracket comprises resilient fingers resiliently pressed against the heat emitting component.

106. The rearview assembly of claim 104, wherein:

the rearview element has at least a portion of the electrical circuit provided directly on the rear surface thereof; and

the at least a portion of the electrical circuit includes the heat emitting component.

107. The rearview assembly of claim 95, further including:

an electrical circuit in the rearview element housing, the electrical circuit including an electrically conductive component;

wherein the crush bracket includes at least a portion thereof contacting the electrically conductive component to provide a ground for the electrically conductive component.

108. The rearview assembly of claim 107, wherein:

the portion of the crush bracket comprises resilient fingers resiliently pressed against the electrically conductive component.

109. The rearview assembly of claim 107, wherein:

the rearview element has at least a portion of the electrical circuit provided directly on the rear surface thereof; and

the at least a portion of the electrical circuit includes the electrically conductive component.

110. The rearview assembly of claim 95, wherein:

the crush bracket compresses at least 1.0 mm without breaking the rearview element as the front surface of the rearview element is subjected to a force no greater than 400 N (90 pounds) in any direction that is not more than 45°

from a forward longitudinal direction of motion of a vehicle having the rearview assembly connected thereto.

111. The rearview assembly of claim 95, further including:

a housing having the rearview element therein;

wherein the rearview element does not contact the housing.

112. The rearview assembly of claim 95, further including:

a connection plate connected to the at least two legs of the crush bracket and the mount.

113. The rearview assembly of claim 112, wherein:

the mount includes a ball adapted to be received within the connection plate to thereby interconnect the mount to the crush bracket.

114. The rearview assembly of claim 112, further including:

a first pivot ball connected to the connection plate and a sleeve connected to the first pivot ball;

wherein the mount includes a second pivot ball connected to the sleeve to thereby interconnect the mount to the crush bracket.

115. The rearview assembly of claim 112, further including:

a housing having the reflecting element, the crush bracket and the connection plate therein;

the housing being frictionally engaged between the mount and the connection plate.

116. The rearview assembly of claim 115, wherein:

the housing does not abut the rearview element.

117. A rearview assembly comprising:

a rearview element;

a support bracket supporting the rearview element;

a rearview element housing; and

a mount connected to the support bracket;

wherein the rearview element supports the rearview element housing and connects the rearview element housing to the mount and the support bracket.

118. The rearview assembly of claim 117, wherein:

the support bracket is a crush bracket.

119. A method of assembling a rearview assembly comprising:

providing a rearview element, a support bracket, a rearview element housing with an opening, and a mount;

connecting the support bracket and the rearview element together;

connecting the mount to the support bracket; and

sliding the rearview element housing over a portion of the support bracket and rearview element, with the portion of the support bracket and the mount sliding through the opening.