Quick-attach mirror mounting structure facilitating assembly

An apparatus includes a mirror head assembly including a rearwardly-extending ball section, and a mirror support assembly including a tube having a larger-diameter mid-section and a smaller-diameter tapered end section. A socket on the mirror support assembly, when in the end section, captures the ball section with friction to permit angular adjustment but with enough friction to maintain a selected angular position. A spring biases the socket from the mid-section into the end section, but is compressible so that assembly is possible by pressing the ball section against the socket, causing the socket to move from the end section into the mid-section where the ball section snaps into the socket. It is conceived that the ball section and socket components can be reversed, and also that the mirror support assembly can include a two-ball mount, with a ball-and-socket connection at each end.

BACKGROUND

The present invention relates to adjustable rearview mirror mounts, and more particularly relates to a ball-and-socket connection on a mirror mount that facilitates assembly.

Most modern vehicle rearview mirrors include a ball-and-socket connection that permits angular adjustment of the mirrors for optimal rear viewing, based on the driver's physical size and individual preferences. The torsional friction generated in the ball-and-socket connections are critical for several reasons, including the need to maintain at least a minimum force of adjustment sufficient to hold a selected angular position, including the need to provide a smooth feel during adjustment so that the customer believes it to be a high-quality mirror, and including the need to stay within an expected range of force of adjustment so that all vehicle drivers are able to make adjustments relatively easily. Also, the force of adjustment must be maintained within the range for the life of the vehicle, despite wear and creeping of materials.

In order to closely control the force of adjustment, many current mirror mount designs require that the ball mount be preassembled to the mirror head (i.e. the mirror housing and components attached to the housing) prior to assembly of the mirror head itself. Preassembly of mounts is commonplace as a way of maintaining tight control over the components that result in the torsional friction of the ball-and-socket connections. However, preassembly of mounts is not a desirable situation, since the mounts and mirror housings include visible surfaces that can be scratched or damaged during subsequent assembly operations. Further, mirrors with preassembled mounts are more difficult to densely package and ship than mirror heads without mounts, since preassembled mounts extend in cantilever a distance from the mirror heads and take up space. It would be preferable to assemble mounts to the mirror at a location closer to the vehicle assembly plant. However, this cannot be done while risking a loss of tight control over the friction of the ball-and-socket connection. Still further, it is desirable to provide a mount construction that is flexible in design so that it can use existing technologies and materials, and so that it does not require the need for higher precision equipment for holding even tighter and more difficult-to-hold dimensional tolerances than already exist. It is also desirable not to add additional parts and cost to the assembly, nor to the ball-and-socket connection itself.

Another concern is energy absorption and distribution of energy by the mirror and mount combination during a vehicle crash. It is desirable to provide a mirror and mount assembly that not only does not pose a potential harm to vehicle occupants during a vehicle crash, but further that actually assists in absorbing energy and at the same time helps reduce any possibility of injury to a vehicle occupant. Also, the mirror and mount combination must not cause potential warranty problems associated with a loose or non-uniformly operating ball-and-socket connection, or that loses its strength over time due to creeping of materials and wear.

Accordingly, an apparatus is desired having the aforementioned advantages and solving the aforementioned problems.

SUMMARY OF THE PRESENT INVENTION

In one aspect of the present invention, an apparatus includes a mirror head assembly, and a mirror support assembly. A ball-and-socket connection includes a ball section on one of the mirror head assembly and the mirror support assembly, and includes a tube and a socket on the other of the mirror head assembly and the mirror support assembly. The socket is shaped to capture the ball section when in a home position in the tube, but is shiftable to a release position in the tube where the socket has room to spread to receive the ball section. A holding device holds the socket in the home position.

In another aspect of the present invention, an apparatus includes a mirror head assembly having a ball section, and a mirror support assembly includes a tube having a mid-section with a larger diameter and an end section with a smaller diameter. The mount support assembly further includes a socket that, when in the end section, is shaped to capture the ball section with friction to maintain a selected angular position but that permits angular adjustment when the friction is overcome. The mirror support assembly includes a spring biasing the socket from the mid-section into the end section. The spring is compressible so that by pressing the ball section against the socket, the socket can be moved from the end section into the mid-section where the ball section snaps into the socket.

In another aspect of the present invention, an apparatus includes a mirror head assembly, and a mirror support assembly. A ball-and-socket connection connects the mirror head assembly to the mirror support assembly. The connection includes a ball section, a tube, and a socket capturing the ball section in an end of the tube for angular adjustment. The socket and ball are shiftable within the tube so that, upon impact against the mirror head assembly, the socket and ball telescope and shift within the tube and reduce angular friction of adjustment before deformation and destruction of the mirror head assembly.

In another aspect of the present invention, an apparatus includes a mirror head assembly, and a mirror support assembly. A ball-and-socket connection connects the mirror head assembly to the mirror support assembly. The connection includes a ball section, a tube, and a socket capturing the ball section in an end of the tube for angular adjustment. The socket and ball are shiftable within the tube so that, upon impact against the mirror head assembly, the socket and ball absorb impact energy before deformation and destruction of the mirror head assembly.

In another aspect of the present invention, a method of assembly comprises steps of providing a mirror head assembly and a mirror support assembly, including a ball section on one of the mirror head assembly and the mirror support assembly, and including a tube and a socket on the other of the mirror head assembly and the mirror support assembly. The method further includes pressing the ball section against the socket to move the socket to a second position where the ball section can be moved inside the socket, and then moving the socket back to a closed home position where the ball section is retained in the socket with frictional engagement that allows angular adjustment but that provides sufficient force to maintain a selected angular position.

In still another aspect of the present invention, a method of assembly comprises steps of providing a mirror head assembly and a mirror support assembly, each including mating connecting structure. The method further includes aligning the mating connecting structure and then pressing the mirror head assembly and the mirror support assembly together to cause the mating connecting structure to interlockingly engage.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

An apparatus20(FIG. 1) includes a mirror head assembly21including a rearwardly-extending ball section22, and a mirror support assembly23. The mirror support assembly23includes a mount24and a tube assembly25. The tube assembly25(FIG. 3) includes a tube section26having a mid-section27defining a larger diameter D1and a frustoconically-shaped tapered end section28defining a smaller diameter D2. A socket29is movable within the tube assembly25and, when in the end section28, captures the ball section22with friction to permit angular adjustment but with enough friction to maintain a selected angular position. An internal coil spring30biases the socket29from the mid-section27into the end section28. The spring30is compressible so that assembly is possible by pressing the ball section22against the socket29, causing the socket29to temporarily move from the end section28into the mid-section27. In the mid-section27, the socket29expands such that the ball section22snaps into the socket29. It is conceived that the ball section and socket components can be reversed, and also that the mirror support assembly can include a two-ball mount, with a ball-and-socket connection at each end, as discussed below. It is also conceived that a holder other than a spring (30) can be used to hold the socket29in its home position within the end section28.

It is contemplated that the present inventive arrangement will work for different combinations of mirror head assemblies and mirror support assemblies, and therefore the present disclosure is not intended to be limited to just the illustrated components. For example, reference is made to U.S. patent application Ser. No. 09/359,144 entitled ELECTROCHROMIC DEVICES WITH THIN BEZEL-COVERED EDGE, and U.S. Pat. No. 6,431,712 entitled REARVIEW MIRROR WITH INTEGRATED FRAME, the entire contents of which are incorporated herein by reference.

The illustrated mirror head assembly21(FIG. 1) includes an internal plate frame32, an electrochromic mirror subassembly33supported on a front of the plate frame32such as by adhesive tape34, and a circuit board35supported on a rear of the plate frame32. The electrochromic mirror subassembly33includes front and rear mirror elements36and37with electrochromic (EC) material38captured therebetween. A housing/back cover39is supported by the plate frame32for aesthetically covering a rear of the mirror head assembly21. The EC material38is operably connected to an electrical circuit on the circuit board34for darkening to reduce glare. A raised flange40is formed on the plate frame32, and includes a flat rear surface and a pair of holes for receiving a locator pin41and an attachment screw42. A one-piece attachment component43, such as a die-cast component, includes a washer-like base44with a center boss44A, a stem45, and the ball section22. A hole46extends through the base44and stem45into the ball section22, for receiving the screw42. The locator pin41extends from the base44, for engaging the mating hole in the raised flange40.

The tube assembly25includes a tube26(FIG. 4) made from a cold finished aluminum alloy. Testing has shown that the aluminum alloy sold by ALCOA as “EXCALIBAR 6013” has been found to be particularly, surprisingly, and unexpectedly well-suited for the present invention due to its strength and ability to resist splitting and damage during assembly. The tube26is initially formed into a tubular shape, and cut to length. Thereafter, one end of the tube26is very accurately deformed (seeFIG. 4) to form the first frustoconically-shaped end section28.

The socket29(FIG. 4) includes a center hub50that is dome shaped, and includes a plurality of fingers51that extend from edges of the hub50to form a crown-like structure. The inner surface of the hub50and the fingers51define a spherical socket shape adapted to closely receive the ball section22, and the outer surfaces52of the fingers51define a frustoconical shape that matches the shape of the frustoconically-shaped end section28.

The spring30is an extensible coil spring that fits within the tube26and engages the socket29, biasing the socket29into the end section28and specifically into the frustoconical shape of the end section28. When in the end section28(FIG. 3), the fingers51are wedgingly biased inward by the angled portions of the frustoconical shape of the end section28, thus providing sufficient inward pressure to cause a frictional resistance to angular adjustment, as required by the ball-and-socket connection formed by the ball section22and socket29. Where desired, an inwardly oriented lip flange53is formed on the end of the end section28of the tube48, to help hide sharp edges of the tube and to help reduce the opening in the end of the tube to a visually-acceptably small size (while still permitting the desired angular adjustment of the ball and socket connection). It is noted that the ends of the fingers51should preferably not bottom out against the inward lip flange53, since the wedging action on the fingers51caused by the spring30biased against the socket29is important to maintaining adequate frictional engagement of the socket29on the ball section22.

The illustrated mirror support assembly23(FIG. 4) comprises a two-ball mount. Specifically, the tube assembly25includes a second socket29A (identical to socket29) fit into a second end section28A of the tube48. The first and second sockets29and29A are fit into the tube26with the spring30compressed therebetween, and the second end section28A of the tube26is then deformed into a frustoconical shape, just like the end section28. (It is not necessary that the ends sections28and28A be identical, nor that the sockets29and29A be identical, but it is advantageous if they are, so as to reduce the number of different components.) Notably, this operation of deforming the end section29A can be done without interference from the mirror head assembly and without interference from the mount component24, thus making this operation much easier to accurately perform and control.

Mount24(FIG. 4) includes a body56, a stem57and a ball section22A. The body56includes a cavity56A shaped to slidably engage and capture edges of an anchoring clip58(FIG. 1) adhered/attached to a vehicle front windshield59. A hole60in the body56(FIG. 4) receives a setscrew to fix the mount24to the clip58. The ball section22A is shaped and sized to mateably engage the socket29A of the tube assembly25. The illustrated mount24includes a slit61that extends along a top of the body56, the stem57and the ball section22A. The slit61permits lay-in of wiring and assists in wire management and routing. The wiring can be extended from the mount24out a side of the stem57and parallel an outside of the tube26to the mirror head assembly21. Alternatively, holes can be put into the sockets and ball sections (seeFIG. 8) to allow wiring to be routed internally through the tube26from the mount24to the mirror head assembly21.

It is contemplated that the mirror head assembly21and the mirror support assembly23will be individually assembled and shipped as separate units, in order to optimize the densities of the components in the ship packages, and to reduce a risk of one component scratching another. It is contemplated that the mirror support assemblies23will have the mount24preassembled to the tube assembly25, though this is not required.

To assemble a mirror support assembly23to a mirror head assembly21, the socket29is positioned against the ball section22(FIG. 5) with the tube assembly25aligned with the stem45so that a “straight-on” assembly motion can be effected. The mirror head assembly21is preferably well-supported and uniformly supported so that the elements36and37do not break (and so that other components do not become scratched and damaged) during assembly of the mirror support assembly23to the mirror head assembly21. The tube assembly25is then moved toward the mirror head assembly21(FIG. 6) causing the socket29against a force of the spring30(i.e. compress the spring30) and to move out of the end section28. As the socket29moves to the larger diameter D1of the mid section27of the tube26, the fingers51of the socket29are permitted to temporarily expand. This expands a size of a leading edge of the spherical cavity defined by the inner surfaces of the fingers51, allowing them to snappingly receive the ball section22. When released, the spring30biases the socket29back into the frustoconically-shaped end section28(FIG. 7), so that the fingers51now frictionally engage the ball section22with the requisite amount of clamping force for a good frictional ball-and-socket connection.

It is contemplated that the present apparatus embodies a very broad and inventive assembly method, including providing a mirror head assembly and a mirror support assembly, each including mating connecting structure, and aligning the mating connecting structure and then pressing the mirror head assembly and the mirror support assembly together to cause the mating connecting structure to interlockingly engage. It is contemplated that the connecting structure can be the ball-and-socket structures described above, or can include other structure that provides a quick-attach mechanism, such as mechanical, chemical, or adhesive bonding methods.

It is contemplated that the present apparatus20provides a novel and non-obvious repair method, which is performed by basically reversing the process of assembly described above. Specifically, for repair, the mirror support assembly23is biased against the mirror head assembly21with sufficient force to cause the socket29to move into the mid-section27. A holder means must then be used to hold the socket29in this retracted position against the bias of the spring30until the ball section22is removed. For example, it is contemplated that a pin could be extended through a small hole in a side of the tube26and into securing engagement with the socket29. Alternatively, where the mount24includes a slit61, the slit61could be used to receive a tool for accessing an inside of the tube26to hold the socket29in a retracted position until the ball section22is removed.

FIG. 8discloses a mirror support assembly23B where the sockets29and29A are modified to include holes70and70A, and where the attachment component43A includes an extended hole46and lateral side hole46A. Wiring71is extended from the mount24through the tube26and attachment component43A into the mirror head assembly21.

FIG. 9shows a “one-ball” mirror supporting assembly in the form of a mount24B having an integral ball section22B integrally formed as part of the material of its body56B and stem57B. The separate tube26is eliminated, and is replaced by a tube26B integrally formed from the material of the internal plate frame32B of the mirror head assembly21B. For example, the plate frame32B can be made of deep-draw material, or can be cast with the tube26B integrally formed as part thereof. Alternative, the tube26B can be fixedly attached to the plate frame32B such as by a screw or other means. An inner end section or “root” of the tube includes a retainer, such as the illustrated integrally-formed inwardly-deformed retainer ring73. The spring30and socket29are initially placed within the tube26and the spring30is compressed, and then the end section28B of the tube26B is deformed into a frustoconical shape to wedgingly retain the socket29in the tapered end section29B of the tube26B. The spring30is held in a compressed state between the tapered end section29B and the retainer ring73, but is compressible to allow the socket30to move out of the tapered end section28B far enough to allow socket fingers51to flex open and allow the ball section22B to snap into the socket29.

The present apparatus has several advantages over prior art that requires pre-assembly of a two-ball mount to a mirror head prior to assembly of internal and external components of the mirror head itself. The present apparatus allows the mirror head assembly to be fully assembled prior to attachment of the tube section (26). The present apparatus further allows for low-cost shipping (i.e. denser packaging and reduced risk of damage during shipment) and permits final assembly at a satellite or remote manufacturing site. The present apparatus further provides for increased room when crimping or inwardly deforming the tapered end section28, since the mirror head assembly21and the mount24are not “in the way”. This added room can result in a direct benefit in terms of better control over and improved accuracy of the crimping and deforming operation. As a result, there can be increased surface area on the interface of the socket29. Specifically, the socket fingers51can have a thicker section, and can extend farther past a center plane of the spherical shape that they define. In other words, the inner surface of the fingers51can includes more surface area to engage opposing sides of the ball section (i.e. to engage the half of the ball section adjacent the mirror head assembly21and the half of the ball section adjacent the mirror support assembly23), thus retaining the ball section better and providing a more uniform frictional support to the ball section. As a result, the apparatus is easier to manufacture and control. The ability to snap-attach both ends of the tube assembly25is also believed to provide significant manufacturing and assembly advantages, including the ability to attach selected mounts chosen from a variety of different mount configurations to various mirror head assemblies having different options thereon.

It is contemplated that the inventive concepts can be used on top mounts as well as rear mounts. The present inventive concepts can also be used on ball-and-socket connections that are offset vertically or horizontally from a center of gravity of the mirror head. The present inventive concepts can be incorporated into small-sized ball sections, such as a 15-mm size of a ball section, or in larger diameters, such as 18-mm or 22-mm ball sections. Various mirror head assemblies can be supported, such as prism mirrors, EC mirrors and non-EC mirrors. The present concepts can be incorporated into outside as well as inside mirrors.

One subtle advantage is believed to be associated with the ability of the socket29to move within the tube26. During a vehicle crash, the mirror head assembly21is permitted to bodily move a small amount toward the vehicle's windshield. This reduces the sharpness of impact of a vehicle passenger against the mirror. As the socket29moves away from the tapered end section28, the socket fingers51experience a loss of support, thus allowing the mirror head assembly21to angularly adjust and/or spin to further reduce its resistance against an impacting object, such as the head of a passenger.