Abstract:
A mirror assembly particularly adopted as a side view mirror for a vehicle, the assembly being provided a mirror, a mounting plate for supporting the mirror, a light assembly having a lens at one end, a visor for accommodating the mirror and the light assembly. A joint element pivotally mounts a side of the light assembly to the mounting plate. The visor has a visor opening into which the lens is fitted, and a connection element for movably connecting an end of the visor opening and an end of the lens. A bias element in the form of a spring pivotally biases the end of the light assembly having the lens such that the connection element substantially closes any gap between the visor opening and the lens.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a vehicle mirror assembly having a light assembly. 
     2. Description of the Related Art 
     Conventionally, an outer, rearview mirror device for a vehicle has been proposed in which a light module is supplementarily installed, with the light module used for illuminating a road surface in the vicinity of a side of the vehicle body. An example in which this kind of prior art is disclosed includes Japanese Patent Application Laid-Open (JP-A) No. 9-48284. 
     In the outer mirror device disclosed in JP-A No. 9-48284 (see especially FIG. 23 of the same), a frame or mounting plate (fixed panel) is accommodated in a visor cover, and a pair of engaging pawls is formed at a lower end portion of the frame. A pair of engaged portions formed in a bridge-like configuration is formed at a surface of the light module in the rear direction of the vehicle to correspond to the engaging pawls. By inserting and engaging the pair of engaging pawls into the pair of engaged portions, the light module is fixed to the frame in a state in which it is accommodated in a space between the visor cover and the frame. 
     However, in the structure disclosed in JP-A No. 9-48284, because the light module is first fixed to the frame, the frame is fixed to the visor cover, and then the light module or the lens is mounted to the visor cover, a substantial step (i.e., a difference in level) is created at a boundary between the lens of the light module and the visor cover. Both the visor cover and the lens of the light module are parts that structure the design surface of the vehicular outer mirror assembly. Therefore, when the dimensional precision of the boundary at which the visor cover and the lens come together is poor, the quality of the outer appearance of the vehicular outer mirror assembly drops. That is, in the vehicular outer mirror assembly disclosed in JP-A No. 9-48284, attention has been given to fixing the light module to the frame but not to the design of the boundary at which the visor cover and the lens of the light module meet. 
     SUMMARY OF THE INVENTION 
     In view of the aforementioned facts, an object of the present invention is to provide, in a structure having a light assembly, an outer mirror assembly for a vehicle in which the quality of the external appearance of the mirror assembly can be improved. 
     In order to solve the aforementioned problems, according to the present invention, there is provided a mirror assembly for a vehicle, the mirror assembly comprising: (a) a mirror; (b) a light assembly having a lens; (c) a visor for accommodating the mirror and the light assembly, the visor having a visor opening into which the lens is fitted; (d) a connection element for movably connecting one end of the visor opening and one end of the lens; and (e) a bias element for biasing the light assembly such that the visor opening is substantially closed by the lens. 
     In accordance with another aspect of the present invention, there is provided a mirror assembly for a vehicle, the mirror assembly comprising: (a) a mirror; (b) a mounting plate for supporting the mirror; (c) a light assembly having a lens; (d) a visor for accommodating the mirror, the mounting plate and the light assembly, the visor having a visor opening into which the lens is fitted; and (e) a joint element for movably connecting the mounting plate and the light assembly. 
     In accordance with yet another aspect of the present invention, there is provided a method for assembling a mirror assembly for a vehicle, said mirror assembly including: (a) a mirror; (b) a mounting plate for supporting the mirror; (c) a light assembly having a lens; (d) a visor for accommodating the mirror, the mounting plate and the light assembly, wherein the visor is provided with a visor opening into which the lens is fitted, the visor comprising a visor rim and a visor cover, with the visor rim including one end of the visor opening and the visor cover including an end opposite to the one end of the visor opening, the method comprising the steps of: (i) movably connecting the light assembly to the mounting plate; (ii) movably connecting one end of the lens and the one end of the visor opening; (iii) mounting the visor rim onto a surface of the mounting plate; (iv) biasing the light assembly such that an opposite end of the mirror abuts against the end opposite to the one end of the visor opening; and (v) mounting the visor cover onto another surface of the mounting plate such that the visor opening is substantially closed by the lens. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a vertical cross sectional view of main portions of a door mirror unit according to an embodiment of the present invention. 
     FIG. 2 is an exploded perspective view of the door mirror unit. 
     FIG. 3 is an enlarged perspective view of an engaging pawl illustrated in FIG.  1 . 
     FIG. 4 is a vertical cross sectional view of a positioning region using the engaging pawl illustrated in FIG. 1, with the view taken along line  4 — 4  in FIG.  3 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     An embodiment of the present invention will be discussed below with reference to FIGS. 1-4. 
     FIG. 2 is an exploded perspective view of an electric-powered retractable door mirror unit  10  according to the present embodiment. FIG. 1 is a vertical cross sectional view of main portions of the door mirror unit in its assembled state. As shown in these drawings, the door mirror unit  10  includes a visor cover  12  having a generally box-shaped configuration that opens toward a rear side of a vehicle and a generally frame-shaped visor rim  14  for covering the open end of the visor cover  12 . Each of the visor cover  12  and the visor rim  14  is formed of a resin material. An outer contour of the door mirror unit  10  is defined by the visor cover  12  and the visor rim  14 . 
     Between the visor cover  12  and the visor rim  14  is provided a mounting plate  16  that is formed of metal and has a generally rectangular plate shape. The mounting plate  16  has a lengthwise slot (hole)  18  at each of its four corners. A resin pawl  20  that is reinforced with a rib is provided at an inner area of the four corners of the visor cover  12  to correspond to the lengthwise slots  18 . By elastically engaging the resin pawls  20  with the lengthwise slots  18 , the visor cover  12  is fixed to the mounting plate  16 . A drive that includes an electric-powered retractable unit, a mirror drive unit, and the like (not shown in the drawings) is mounted on the mounting plate  16 . 
     The visor rim  14  comprises a frame  22 , which forms an outer shape (design surface) of the visor rim  14 , and a partition wall  26 , which is formed at an intermediate portion within the frame  22  and has a relatively large opening  24  formed in a center of the partition wall  26 . A through-hole  28  is formed at four corners of the partition wall  26 , and through-holes  30  are formed at appropriate positions of the mounting plate  16  to correspond to the through-holes  28 . By passing screws (not shown) through the through-holes  28  and  30 , the visor rim  14  is fixed to the mounting plate  16  in a state in which the visor rim  14  is engaged with the visor cover  12 . 
     A rear-view mirror  32  is provided at the side of the partition wall  26  in the visor rim  14  that faces the rear of the vehicle. The mirror  32  is connected to a mirror drive unit (not shown) through the opening  24  formed in the partition wall  26 . 
     As shown in FIG. 1, a light assembly  34  is disposed in an inclined state at a lower portion of a space created by the visor cover  12 , the visor rim  14  and the mounting plate  16 . The light assembly  34  comprises a light source  36 , a generally box-shaped reflector  38  for directing diffused light from the light source  26  in a fixed direction, and a lens  40  to irradiate light by refracting light toward a target position. The light source  36  is mounted at a bottom portion of the reflector  38 , and the lens  40  is mounted at an open end (lower end portion) of the reflector  38 . 
     An engaged portion  42  that has a generally C-shaped configuration when seen in cross section is formed at a substantial center of a back wall  38 A in the reflector  38 . Further, a tongue-shaped engaging protrusion  44  is formed at a substantial center of a lower end of the mounting plate  16 , with the engaging protrusion  44  corresponding to the engaged portion  42 . The engaging protrusion  44  is bent at an intermediate region thereof. By inserting the engaging protrusion  44  into the engaged portion  42 , the light assembly  34  is engaged with (provisionally attached to) the mounting plate  16 . 
     An abutment support  46  that has a substantially triangular configuration when seen from the side is integrally formed at an inner, central bottom region of the annular junction between the frame  22  and the partition wall  26 . The abutment support  46  has an inclined surface  46 A (see FIG. 1) that abuts against a back wall  38 A of the reflector  38 . By this abutment of the abutment support  46  against the back wall  38 A of the reflector  38 , the state in which the light assembly is mounted is stabilized more effectively. Further, the abutment support  46  also serves as a guide during mounting of the light assembly  34 . 
     In a state in which the visor rim  14  is fitted over the visor cover  12 , a visor opening  48  having a generally rectangular configuration is formed at a lower end of the visor rim  12 . To describe in more detail, a notch  50  (see FIG. 2) having a curved configuration is formed at a lower end of the visor cover  12 , and a peripheral portion in which the notch  50  is formed is a front peripheral portion  48 A of the visor opening  48 . Further, as shown in FIG. 1, a lower end of the visor rim  14  is formed in a generally C-shaped configuration, and a lower peripheral end thereof is a rear peripheral portion  48 B of the visor opening  48 . Moreover, a cross sectional configuration of the front peripheral portion  48 A forms a predetermined concave shape (see FIG.  1 ), and a cross sectional configuration of the rear peripheral portion  48 B forms a predetermined concave shape (see FIGS. 1 and 4) that is different from that of the cross sectional configuration of the front peripheral portion  48 A. 
     The lens  40  of the light assembly  34  is fitted into the visor opening  48  having the structure described above. To describe in more detail, a pair of resin engaging pawls  52  (only one illustrated in FIGS.  3  and  4 ), each of which has a generally L-shaped configuration when seen in cross section, is integrally formed at the rear end  40 A of the lens  40 . As shown in FIG. 4, the rear peripheral end  48 B of the visor opening  48  in the visor rim  14  (at both sides of the abutment support  46 ) is inserted into the engaging pawl  52 . Further, the front end  40 B of the lens  40  is formed in a predetermined protruding configuration when seen in cross section, and the front end  40 B abuts against the front peripheral portion  48 A of the visor opening  48 . 
     The reflector  38  has a front wall  38 B which is opposed to the back wall  38 A. A spring fixing portion  54 , into which is fitted a pressing spring  56 , is formed integrally at a lower center of the front wall  38 B of the reflector  38 . The pressing spring  56  comprises a plate spring, and has a proximal end  56 A which is inserted and fixed into the spring fixing portion  54  and a free end  56 B formed in a curve opposite the proximal end  56 A. The free end  56 B curves in such a manner that resembles a generally V-shaped configuration, and has a tip  56 B′. 
     A pressing protrusion  58  that has a rectangular plate-shaped configuration is formed integrally with the visor cover  12  at a position above the notch  50 . When the light assembly  34  is assembled with the visor cover  12  and the visor rim  14 , a tip  58 A of the pressing protrusion  58  abuts and presses against the tip  56 B′ of the free end  56 B of the pressing spring  56 . Accordingly, the free end  56 B of the pressing spring  56  is elastically deformed toward the front wall  38 B. 
     An operation and effect of the present embodiment will next be described. 
     The door mirror unit  10  pertaining to the present embodiment is assembled as described below. 
     A drive unit (not shown) is set on the mounting plate  16 . Thereafter, the light assembly  34  is provisionally secured on the mounting plate  16 . Specifically, the engaging protrusion  44  of the mounting plate  16  is inserted and hooked into the engaged portion  42  of the light assembly  34  such that the mounting plate  16  supports the light assembly  34  in a dangling state. Next, the visor rim is fixed to the mounting plate  16  with screws (not shown), and then the mirror  32  is mounted on the visor rim  14 . 
     At this time, the pair of engaging pawls  52  formed on the rear end  40 A of the lens  40  is inserted into and engaged with the rear peripheral portion  48 B of the visor rim  14 . Further, the inclined surface  46 A of the abutment support  46  of the visor rim  14  abuts against the back wall  38 A of the reflector  38 , whereby the light assembly is stably supported. 
     Thereafter, the proximal end  56 A of the pressing spring  56  is inserted into the spring fixing portion  54  of the light assembly  34 . Finally, the visor cover  12  is mounted on the mounting plate  16  such that the engaging pawls  20  of the visor cover  12  are inserted into the slots of the mounting plate  16 . 
     Accordingly, the visor cover  12  is fitted over the visor rim  14  to form the visor opening  48  for mounting of the lens, whereby the lens  40  is completely mounted to the visor opening  48 . As described above, the pair of engaging pawls  52  engages with the rear peripheral portion  48 B of the visor rim  14 , whereby the rear end  40 A of the lens  40  is positioned with respect to the rear peripheral portion  48 B of the visor rim  14  and the front end  40 B of the lens  40  abuts against the front peripheral portion  48 A of the visor cover  12 . 
     Additionally, the above assembling process is only one example. In place thereof, any other process can be widely employed to assemble a door mirror unit. 
     In a state in which the door mirror unit  10  is assembled in the manner described above, the visor cover  12 , the visor rim  14 , and the lens  40 , together with the mirror  32 , form exposed outer surfaces. The visor cover  12 , the visor rim  14  and the lens  40  form the primary design surface of the door mirror unit  10 . 
     In the present embodiment, when the door mirror unit  10  is assembled, the tip  58 A of the pressing protrusion  58  formed inside the visor cover  12  abuts and presses against the tip  56 B′ of the free end  56 B of the pressing spring  56  such that the free end  56 B is elastically deformed in a direction in which a distance between the free end  56 B and the proximal end  56 A becomes smaller. 
     Incidentally, the pair of engaging pawls  52  formed at the rear end  40 A of the lens  40  engages with the rear peripheral portion  48 B. A rotational force around this engagement point is generated due to an elastic restoring force of the pressing spring  56 , with the rotational force being applied to the light assembly  34  such that the light assembly  34  rotates in the direction of arrow A in FIG.  1 . 
     Thus, the front end  40 B of the lens  40  of the light assembly  34  is pressed onto the front peripheral portion  48 A of the visor cover  12 . Namely, the front end  40 B of the lens  40  abuts against the forward peripheral portion  48 A of the visor cover  12 . The abutment of the front end  40 B and the front peripheral portion  48 A forms a curved boundary between the lens  40  and the visor cover  12 , with the portion at which the two oppose each other forming a step, or difference in level. Generally, such a step may vary depending on several factors, i.e., dimensional errors, fittedness, securing manner, etc. In the present embodiment, however, the step can be stably and reliably maintained at a desired accuracy under the influence of the rotational force or bias force that is applied to the light assembly  34 . Therefore, the primary design surface (external appearance) of the door mirror unit  10  is not compromised. The door mirror unit  10  provided with the light assembly  34  according to the present embodiment does not sacrifice the quality of the unit&#39;s external appearance. Namely, the quality of appearance of the door mirror unit  10  is improved. 
     Further, in the present embodiment, when the door mirror unit  10  is assembled, the pressing spring  56  is elastically deformed due to the interaction between the pressing spring  56  that is formed by a plate spring and the pressing protrusion  58  that is formed integrally with the visor cover  12 . The deformation of the pressing spring  56 A produces a spring bias force applied to the light assembly  34  around the connection of the rear end  40 A of the lens  40  and the rear peripheral portion  48 B of the visor rim  14 . The rotational force stabilizes the abutment between the lens  40  and the visor cover  12 , and the strength of the abutment is neither too strong nor too weak. Namely, a desired accurate step at the region where the lens  40  and the visor cover  12  abut against each other can easily be obtained without imparting damage to both the front end  40 B of the lens  40  and the front peripheral portion  48 A of the visor cover  12 . 
     It is conceivable that a light assembly can be directly fixed to a visor cover, such as the door mirror device disclosed in, for example, Japanese Utility Model Application Laid-Open (JP-U) No. 61-129645. In this case, because the light assembly is fixed in a state in which the light assembly slants with respect to an underside of the visor cover, there is the problem that assembly of the light assembly to the visor cover becomes extremely burdensome. 
     It should be noted that, in the door mirror device disclosed in JP-U No. 61-129645, an opening for replacement of parts is provided at a front surface portion of the visor cover, and a lid is fitted therein. While it is conceivable to assemble the light assembly to the underside of the visor cover while the lid is open, providing a lid at the visor cover become a necessary condition and there is the drawback that the structure grows more complex. 
     By contrast, in the door mirror unit  10  according to the present embodiment, the light assembly  34  is provisionally secured not to the visor cover  12  but to the mounting plate  16  through the engaging protrusion  44  and the engaged portion  42 . In the process of assembly, the light assembly  34  is provisionally secured to the mounting plate  16 , and the lens  40  is then positioned with respect to the visor opening  48  when the visor rim  14  is secured to the mounting plate  16 . Thereafter, steps may be taken to ensure that the assembly is completed. As a result, according to the present embodiment, the structure does not become unnecessarily complex, and assembly of the light assembly can be improved. 
     Further, in comparison with a case in which both the positioning and assembly of the mounting plate  16  and the light assembly  34  are completed at a time, the present embodiment leaves room for final adjustment of the positioning of (the front end  40 B of) the lens  40  with respect to (the front peripheral portion  48 A of) the visor cover  12 . Therefore, from this point of view, it becomes possible to keep the step formed at the boundary between the periphery of the visor opening and the periphery of the lens to a minimum with the invention of the present embodiment. Hence, in a structure provided with the light assembly  34 , the quality of the external appearance of the door mirror unit  10  can be improved. 
     In the present embodiment, the light assembly  34  for illuminating a road surface in the vicinity of a side of a vehicle is situated in the visor opening  48  formed in the lower part of the visor cover  12  and the visor rim  14 . However, the present invention is not limited to the same. The opening can be formed at another predetermined position on the visor. For example, together with the light assembly used in the present embodiment, a compact light assembly with a miniature lens may be additionally provided, with the miniature lens being disposed on a side portion of the door mirror visor and the larger light assembly being disposed at the underside of the door mirror visor for illuminating obstacles in order to measure the distance between the vehicle body and the obstacle at a given time (e.g., when the vehicle is put into a garage). In this sense, such a structure may also be included within the scope of the present invention. To supplement this point, the present invention includes not only an illumination device (lighting device) such as a lamp for underfoot lighting and a car width lamp for indicating vehicular width, but also includes a flash device such as a (supplementarily installed) turn signal lamp. 
     In the embodiment described above, the pressing spring  56  is mounted at the light assembly  34  and the pressing protrusion  58  is provided at the visor cover  12 . However, the present invention is not limited to the same. A reverse structure may also be adopted. Namely, the pressing spring  56  can be mounted at the visor cover  12  and the pressing protrusion can be provided at the light assembly  34 . In this case also, an action and effect substantially the same as those of the present embodiment may be obtained. 
     Further, in the present embodiment, the mutual action of the pressing spring  56  and the pressing protrusion  58  generates a rotational force that drives the light assembly  34  to rotate around the engaging point including the engaging pawls  52 . In place of this structure, there can be provided a tension spring which produces a pulling force such that the light assembly  34  is drawn into the interior of the visor cover  12  (in an upward direction). 
     In relation to the preceding, the pressing spring  56  comprising the plate spring is used in the present embodiment. However, the present invention is by no means limited to the same. Another type of spring such as a coiled tension spring, a coiled compression spring or a Belleville spring may be used. A rubber having a predetermined hardness may also be used as a rotational force-generating member or biasing means. 
     Further, in the present embodiment, a pair of hook-shaped (i.e., generally L-shaped) engaging pawls is used for positioning or connection. However, the present invention is not limited to the same. In place thereof, a structure in which it is possible to position or connect one end of the lens to one peripheral portion of the visor may also be employed. 
     Moreover, in the present embodiment, the lens  40  has the pair of engaging pawls  52  formed at the lens  40 . However, engaging pawls may be provided at both the lens and the visor rim so that they are mutually positioned with respect to each other. 
     Yet further, the invention is applied to a door mirror unit  10 . However the present invention is not limited to the same. The present invention may also be applied to a fender mirror.