Consolidated exterior sideview mirror assembly incorporating an in-mold film process

• US 6,447,130 B2
• Filed: 06/15/2001
• Issued: 09/10/2002
• Est. Priority Date: 05/01/2000
• Status: Expired due to Fees

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Chu, Tun-Jen
• Primary Examiner(s): SIKDER, MOHAMMAD YUNUS
• Application Number:
  US09/882,763
• Publication Number:
  US 20020012181A1
• Time in Patent Office: 452 Days
• Field of Search: 359/883, 359/884, 428/79, 428/68, 428/31, 156/61, 156/63, 156/245, 156/277, 264/132, 264/133, 264/241, 264/259, 264/297.2, 427/8, 427/162, 427/407.1, 406/68, 406/611.1, 406/610.4, 403/15
• US Class Current: 359/883
• CPC Class Codes: B60R 1/06 mounted on vehicle exterior B60R1/025, B60R1/08 take precedence

Abstract

A method of forming a mirror housing according to the present invention includes providing a molding apparatus having a molding cavity, placing a film appliqué in the mold cavity and injecting a polymer into the mold cavity over at least a portion of a side of the film appliqué to form a housing wall of the mirror housing wherein the film appliqué adheres to the substrate forming the housing wall. Preferably, the mold apparatus comprises an injection molding apparatus which injects a heated polymer into the mold cavity for forming the housing wall of the mirror housing. The film appliqué preferably matches the color of the vehicle or provides a color accent, wood grain finish, or a metallic finish or the like to provide a decorative appearance to the mirror assembly but without the noise associated with the conventional detachable skull cap designs. The present invention also provides a vehicular exterior sideview mirror assembly which includes a mirror housing that is adapted for mounting to a vehicle. The mirror housing is formed by molding and has a housing wall that defines a cavity and an opening for facing rearward of the vehicle when the mirror assembly is mounted to the vehicle. A reflective element is provided in the cavity for rearward viewing of the vehicle. In addition, the mirror housing has a forward facing side when the mirror assembly is mounted to the vehicle with at least a portion of the forward facing side including a decorative film appliqué molded therewith to provide a decorative function for the mirror assembly.

Claims

1. A method of forming a housing for a vehicle mirror assembly comprising:

providing a molding apparatus having a mold cavity;

placing a film appliqué

in the mold cavity; and

injecting a polymer substrate into the mold cavity over at least a portion of a side of the film appliqué

to form a housing wall wherein the film appliqué

adheres to the substrate forming the housing wall.

2. The method of forming a housing according to claim 1, wherein the film appliqué

adheres to the substrate by at least one of mechanical adhesion, physical adhesion, and chemical adhesion.

3. The method according to claim 1, wherein said providing a molding apparatus includes providing an injection molding apparatus, said injecting includes injecting a heated polymer into the mold cavity.

4. The method according to claim 3, wherein the film adhesion is assisted by heat in the mold cavity.

5. The method according to claim 1, further comprising restraining said film appliqué

in the mold cavity when injecting the polymer substrate into the mold cavity.

6. The method according to claim 5, further comprising configuring the mold cavity to restrain the film appliqué

in the mold cavity when injecting the polymer substrate into the mold cavity.

7. The method according to claim 6, wherein said configuring includes forming a projection on a side of the cavity, the projection assisting holding the film appliqué

in the mold cavity.

8. The method according to claim 7, wherein said forming a projection includes forming a ridge around at least a portion of an area of the side of the cavity, the area being sized to assist holding the film appliqué

in the mold cavity.

9. The method according to claim 8, wherein said forming includes forming a peripheral ridge around the area.

10. The method according to claim 5, wherein said restraining includes applying a vacuum hold on the film appliqué

.

11. The method according to claim 5, wherein said restraining includes conforming the film appliqué

to a portion of the mold cavity.

12. The method according to claim 11, wherein said conforming includes injecting a gas into the mold cavity to conform the film appliqué

to the portion of the mold cavity prior to injecting the polymer.

13. The method according to claim 1, wherein said injecting a polymer substrate includes injecting a polymer substrate substantially over an entire side of the film appliqué

.

14. The method according to claim 1, further comprising providing an adhesion promoter on the portion of the film appliqué

.

15. A housing for a vehicle mirror assembly formed according to the method of claim 1.

16. A housing for a vehicle mirror assembly formed according to the method of claim 2.

17. A housing for a vehicle mirror assembly formed according to the method of claim 13.

18. The method according to claim 1, wherein said placing a film appliqué

includes placing a pre-formed film appliqué

in a mold cavity.

19. The method according to claim 1, wherein said placing a film appliqué

comprises placing a decorative film appliqué

to provide a decorative function for the mirror assembly.

20. The method according to claim 19, wherein said placing a film appliqué

includes placing a pre-formed decorative film appliqué

to provide a decorative function for the mirror assembly.

21. The method according to claim 1, wherein said placing a film appliqué

includes placing a film appliqué

which comprises a laminate including at least one backing sheet and at least one coating over said backing sheet.

22. The method according to claim 21, further comprising matching the coating with the vehicle body paint.

23. The method according to claim 22, further comprising providing an accent color with said coating.