SHATTER-PROOF REAR VISION MIRROR ASSEMBLY FABRICATION

• US 3,776,618 A
• Filed: 03/06/1972
• Issued: 12/04/1973
• Est. Priority Date: 03/06/1972
• Status: Expired due to Term

• Current Assignee: Ronald C. Sr. Perison
• Original Assignee: Ronald C. Sr. Perison
• Inventors: Perison, Ronald C. Sr.
• Primary Examiner(s): Schonberg, David
• Assistant Examiner(s): Tokar, Michael J.
• Application Number:
  US05/232,117
• Time in Patent Office: 638 Days
• Field of Search: 350/288,303,304,307,320
• US Class Current: 359/870
• CPC Class Codes: B60R 1/04 mounted inside vehicle B60R1/025, B60R1/08 take precedence
• CPC Class Codes: B60R 1/086 using a mirror angularly movable between a position of use and a non-glare position reflecting a dark field to the user, e.g. situated behind a transparent glass used as low-reflecting surface; Wedge-shaped mirrors
• CPC Class Codes: G02B 5/08 Mirrors vehicle mirrors involving special optical features B60R1/08

Abstract

A shatter-proof rear vision mirror assembly is fabricated from a pre-formed plastic casing molded with a mounting in situ and having a cavity into which is poured a self-foaming liquid prior to closing of the cavity by installation of a mirror panel, whereupon the casing and panel act as a mold in which the liquid foams to form a foamed in situ backing filling the cavity between and bonded to both the casing and panel.

Claims

1. A SHATTER-PROOF REAR VISION MIRROR ASSEMBLY INCLUDING A MOUNTING, A CASING, A MIRROR PANEL AND A PLIANT FOAMED BACKING BETWEEN SAID CASING AND PANEL, WHEREIN THE IMPROVEMENT COMPRISES:

SAID CASING BEING PRE-FORMED FROM SUITABLE PLASTIC MATERIAL, SUCH AS POLYPROPYLENE OR POLYVINYL CHLORIDE, MOLDED WITH SAID MOUNTING IN SITU, TO FORM AN ENLARGED RECESSED CENTRAL WALL PORTION HOUSING SAID MOUNTING, A CAVITY, AN INTERNAL PERIPHERAL GROOVE, AND OUTSTANDING INTERNAL WALL PORTIONS, SAID BACKING BEING FORMED FROM SUITABLE SELF-FOAMING LIQUID, SUCH AS POLYURETHANE, POURED INTO SAID CAVITY PRIOR TO INSTALLATION OF SAID PANEL, SAID PANEL BEING INSTALLED, BY INSERTING THE SAME INTO SAID GROOVE AND BY POSITIONING THE SAME AGAINST SAID INTERNAL WALL PORTIONS, TO CLOSE SAID CASING OVER SAID LIQUID AND TO ACT WITH SAID CASING AS A MOLD CONFINING SAID LIQUID DURING FOAMING, AND FOLLOWING SAID FOAMING SAID BACKING FILLING SAID CAVITY BETWEEN AND BONDED TO SAID CASING AND PANEL.

2. The assembly of claim 1 wherein said central wall portion is provided with an inset socket housing said mounting separate from said backing and outstanding internal reinforcing ribs radiating from said socket, said internal wall portions divide said cavity into two outer portions and a central portion opposite said ribs and include lugs supporting said panel and recesses between said lugs, said panel is snapped into said groove, and said backing is formed by foaming of said liquid throughout each of said cavity portions and recesses following said installation of said panel.

3. The assembly of claim 1 wherein said internal wall portions divide said cavity into outer portions and a central portion housing said mounting within said central wall portion, separate from said backing, which is formed by foaming of said liquid throughout said outer cavity portions only.

4. The assembly of claim 3 wherein the back of said panel is reinforced by tape spanning said central cavity portion and internal wall portions.

5. A method of fabricating a shatter-proof rear vision mirror assembly including a mounting, a casing, a mirror panel and a pliant foamed backing between said casing and panel, wherein the improvement comprises, in sequence:

providing said casing pre-formed from suitable molded plastic material, such as polyprophylene or polyvinyl chloride, molded with said mounting in situ, to form an enlarged recessed central wall portion housing said mounting, a cavity, an internal peripheral groove, and outstanding internal wall portions, pouring suitable self-foaming liquid, such as polyurethane, into said cavity, installing said panel, by inserting the same into said groove and positioning the same against said internal wall portions, to close said casing over said liquid and to act with said casing as a mold confining said liquid during foaming, and foaming of said liquid to form said pliant backing filling said cavity between and bonded to said casing and panel.

6. The method of claim 5 wherein said central wall portion is provided with an inset socket housing said mounting separate from said backinG and outstanding internal reinforcing ribs radiating from said socket, said internal wall portions divide said cavity into two outer portions and a central portion opposite said ribs and include lugs supporting said panel and recesses between said lugs permitting said liquid to foam throughout each of said cavity portions following snapping of said panel into said groove.

7. The method of claim 5 wherein said internal wall portions divide said cavity into two outer portions and a central portion housing said mounting within said cental wall portion separate from said backing, and said liquid is poured into said outer cavity portions only, followed by snapping of said panel into said groove and said foaming of said liquid in said outer cavity portions only.

8. The method of claim 7 wherein the back of said panel is reinforced by tape spanning said central cavity portion and said internal wall portions.