Trapped cutline gasket for external side mirror

An external side mirror is pivotable relative to a vehicle to which it is attached. The external side mirror includes an outer cover, and a housing bracket within the outer cover. The housing bracket is mounted or attached to the outer cover. A gasket is removably attached to the underside of the housing bracket. The gasket has a plurality of hooks that extend upwardly and attach to the housing bracket. Support ribs extending from the outer cover trap the hooks against the housing bracket. This allows the gasket to pivot along with the external side mirror relative to the vehicle to keep the gasket hidden from view even when the external side mirror is pivoted.

TECHNICAL FIELD

This disclosure generally relates to a gasket for an external side mirror of a vehicle. In particular, the gasket is mounted within the mirror such that the gasket rotates with the mirror as the mirror rotates relative to the vehicle.

BACKGROUND

Passenger vehicles such as cars typically include sideview mirrors, also known as outside rearview mirrors or external side mirrors. External side mirrors are typically mounted outside the vehicle cabin to allow the driver to see the environment to the side and behind the vehicle. These mirrors can be foldable or pivotable relative to the remainder of the vehicle. The mirrors can be folded inward when, for example, the vehicle is parked so as to protect the mirrors from accidental collision or impact from other vehicles passing by.

SUMMARY

In one embodiment, an external side mirror is configured to rotate relative to a connected vehicle. The external side mirror includes an outer cover, and a housing bracket within the outer cover. The housing bracket has a lower flange defining an upper surface and a lower surface. A gasket has a base mounted to the lower surface of the lower flange. The gasket includes a plurality of hooks extending upward therefrom and attached to the upper surface of the lower flange.

The lower flange may have a perimeter with the hooks being spaced about the perimeter. The lower flange may define an opening sized to receive power electronic wiring, and the gasket may define an opening aligned with the opening in the lower flange. The gasket may be made of rubber and the hooks may be integrally-formed with the gasket. The gasket may include an upper surface, a lower surface, and a perimeter edge, wherein the hooks extend from the perimeter edge. The gasket may have a flange extending along a periphery of the lower surface. The outer cover may include a lower cover and a skull cap with a cutline gap between the skull cap and a base assembly of the vehicle. The gasket may seal the cutline gap.

In another embodiment, a gasket for an external side mirror includes a base having a top surface, a bottom surface, and an edge surface about a perimeter of the gasket. A lip is integral with the base and extends downward from the bottom surface about the perimeter. At least a portion of the lip is located such that it is configured to seal against a base assembly of a vehicle. A plurality of hooks are integral with the base about the perimeter and are configured to engage a flange of a housing bracket of the external side mirror. The hooks have a first portion extending transverse from the edge surface, a second portion extending upward and transverse from the first portion, and a top portion extending inward from the second portion. The top portion has a lower surface configured to contact the flange of the housing bracket of the external side mirror.

In yet another embodiment, an external side mirror assembly for a vehicle includes a lower cover, and a skull cap connected to the lower cover. The skull cap has a lower edge configured to at least partially define a cutline gap between the skull cap and a base assembly of the vehicle. A housing bracket is within an interior of the connected lower cover and skull cap. The housing bracket has a lower surface and an upper surface. A gasket is removably mounted to the housing bracket. The gasket includes an upper surface contacting the lower surface of the housing bracket. The gasket is aligned with the cutline gap to seal the cutline gap with respect to the interior of the connected lower cover and skull cap.

DETAILED DESCRIPTION

Directional terms used herein (e.g., “upper,” “lower,” “inner,” “outer,” “top,” “bottom,” etc.) are intended to refer to the orientation of how the various components are illustrated in the Figures, and how the mirror disclosed herein is oriented relative to an upright vehicle. These terms are intended for contextual purposes.

FIG. 1shows a partial view of a front driver-side of a vehicle10having a sideview mirror12, also known as an external side mirror. The vehicle10is a passenger vehicle such as a car, van, truck, SUV, or the like. The external side mirror12is on the outside of the vehicle10, and can also be referred to as an outside or external rearview mirror, a wing mirror, and other terms known in the art to refer to such a mirror. The external side mirror12has a reflective mirror14that can have an adjustable orientation, but typically faces the side of the vehicle to give a driver a view of the surroundings on that rearward side of the vehicle.

Some external side mirrors in the art are adjustable relative to the vehicle. For example, some external side mirrors can pivot or swivel to face inward (e.g., when the vehicle is parked) or outward. For example, inFIG. 1, the external side mirror12is shown in use position or drive position, and the broken lines represent a parked position or folded position. The pivoting of the mirrors can be accomplished manually or automatic via a motor and associated structure. For example, in some vehicles, the pivoting of the mirror can be done automatically in response to the vehicle being turned off, in park, etc. This can reduce the chance of potential damage done to the mirror from things such as passing vehicles or environmental elements.

To enable the pivoting or swiveling, some mirrors (including embodiments of the external side mirror described herein) have a mount or base assembly16that is fixed to the vehicle body and an overlying cover18that is pivotally connected to the base assembly16. The cover18at least partially surrounds the reflective mirror14and the accompanying motor, gears, electronics, etc. that are within the external side mirror. A small gap may exist between the base assembly16and the cover18to allow for the pivoting of the cover18. This gap may be referred to as a cutline. If left unaccounted for, wind passing over or through this cutline can cause a whistle, especially at certain high vehicle speeds. Attempts have been made to place a gasket at this cutline. However, the current gaskets have issues with assembly, and mount in an insufficient manner to properly prevent the wind noise. Furthermore, when the skull cap pivots, the gaskets are visible which is visually undesirable.

Therefore, according to various embodiments of this disclosure, a new cutline gasket for an external side mirror is provided. As will be explained below, the gasket fits in the cutline between the base cover and the skull cap to reduce or eliminate any noise from wind passing over the cutline. The gasket mounts in an improved manner to provide various benefits, including an improved reduction in the noise from wind over the cutline, as well as reducing or eliminating the visibility of the gasket when the mirror is pivoted to face the vehicle.

Referring to an embodiment shown inFIGS. 2-6, an external side mirror20is shown disassembled in an exploded view (inFIG. 2) and assembled (inFIGS. 3-4). A gasket (described below) within the external side mirror20is shown in isolation inFIGS. 5-6. The external side mirror20includes at least some of the structure and function of the external side mirror12described above, with additional detail and structure described below. The external side mirror20includes a lower cover22(also referred to as a base cover). The external side mirror also includes a skull cap24(also referred to as an upper cover, a main cover, a top cover, or an overlying shell) connected to the lower cover22. The cover22, and skull cap24can collectively be referred to as a cover or outer cover. The skull cap24at least partially surrounds a reflective mirror, not shown inFIG. 2due to the orientation of the mirror. The skull cap24may include a recess or opening26with an associated light source28to provide as a turn signal. The lower cover22may include an illuminated logo, camera, puddle lamp, or other type of light known to those in the art as being part of an external side mirror.

A housing bracket30is mounted within the skull cap24and connects to an interior portion of the skull cap24as will be described with reference toFIG. 3. The housing bracket30can be made of plastic (e.g., injection-molded), carbon fiber, aluminum, steel, or other like materials. The housing bracket30includes a central opening32to protect and guide electronic wires and mechanical connections for connection to a motor, lights, and/or other components within the external side mirror20. The housing bracket30has a lower flange34that defines a lower part of the opening32. A portion of the flange is connected to the lower cover22, and another portion of the flange is connected to the skull cap24, as will be further described below. This indirectly connects the skull cap24to the lower cover22.

The flange34has a periphery or perimeter36that is located within the confines of the skull cap24. However, a large portion of the flange34and its perimeter36are located outside the confines of the lower cover22. For example, inFIG. 2it can be seen that the lower cover has a curved surface38that curves inwardly toward the interior of the mirror, and the flange34rests vertically above the space outside of this curved surface38of the lower cover22. The skull cap24has a curved surface40that curves outwardly and extends beyond the curved surface38of the lower cover22to cover the perimeter36of the housing bracket30. This allows for the wires and mechanical connections (described above) to pass through the opening32of the housing bracket30and into the interior of the skull cap24without passing through the lower cover22.

A mount or base assembly44may also be provided that is fixed to a portion of the vehicle, such as the vehicle door. The base assembly44may extend laterally from the mirror to the vehicle, and also vertically into the opening32of the housing bracket30, between the curved surface38of the lower cover22and the curved surface40of the skull cap24. The external side mirror20is pivotally connected to the base assembly44to allow the external side mirror20to pivot or rotate relative to the vehicle, as described above. Also as described above, the interface between the base assembly and the external side mirror20may define a gap or cutline to provide clearance for the pivoting.

To account for, among other things, the undesirable wind noises at the cutline that might otherwise occur (as described above), a cutline gasket42is provided. The gasket42fills the cutline void or gap, and is trapped between the skull cap24and lower cover22. The gasket42also seals this gap from external environmental conditions, such as rain, dirt, debris, etc. And, since the gasket42is attached to the housing bracket30from beneath, the gasket42swivels with the housing bracket when the external side mirror20is swiveled; this prevents the gasket from being visible when the external side mirror20is swiveled, improving the aesthetic appearance of the mirror when the vehicle is parked, for example.

In one embodiment, the gasket42is made from a synthetic rubber material, with sufficient flexibility yet providing the proper seal at the cutline.

The gasket42has a generally planar base46, and a flange or lip48about its perimeter. The lip48extends slightly below a lower edge49of the skull cap24, and acts as the surface that contacts the lower cover22and the base assembly44to create the seal. The base46also defines a central void or opening50sized similar to the opening32of the housing bracket30. The opening50allows the electronic wires, etc. to pass therethrough, as described above. In one embodiment, the gasket42has a first curved region52that matches the profile of the curved surface38of the lower cover22, and an opposing second curved region54that matches the profile of the curved surface40of the skull cap24. The first curved region52has a larger radius of curvature than that of the second curved region54, and is interior of the second curved region54. A perimeter56of the gasket42may fit and abut the interior of the flange34of the housing bracket30such that the perimeter36of the flange34of the housing bracket30contains the gasket42. The specific shape and dimension of the gasket42and its opening32is illustrated according to one embodiment, but can be altered to fit various external side mirrors.

The gasket42has a plurality of hooks or fingers60extending from the perimeter56. The gasket42directly contacts the flange of the housing bracket from beneath, and the hooks60wrap around the perimeter edge56and contact the upper surface of the flange34. In another embodiment, the hooks60extend through openings or apertures in the flange instead of wrapping around the peripheral edge of the flange. The hooks60extend upwardly when assembled such that the hooks are configured to engage with the housing bracket30(e.g., the upper surface of the flange) to mount the gasket42to the housing bracket30from beneath, as seen inFIGS. 3-4. The hooks60may be an integrally-formed extension of the gasket and made of the same material (e.g., rubber) as the gasket. Referring toFIGS. 3, 4, and 6, the hooks60include a first linear portion62extending transversely from the outer edge surface of the gasket42. A second linear portion64extends transversely from the first linear portion62and upward (e.g., when assembled). A tapered cap or top portion66extends inwardly from the second linear portion64. The top portion66may be triangular in shape. A gap67exists between the top portion66and the first linear portion62that is sized to receive a portion of the flange34of the housing bracket30. The top portion66has an underside68that engages with the upper surface of the flange34of the housing bracket30.

To assemble the gasket42within the external side mirror, the gasket42is placed against the underside of the housing bracket30oriented such that the first curved region52faces the curved surface38and the second curved region54faces the curved surface40of the skull cap24. The hooks60extend upwardly into the mirror assembly and hook onto a notch or cut-out61of the flange34of the housing bracket30. The hooks60are of sufficient rigidity to hold their shape, yet flexible enough relative to the main body of the gasket42so that they can bend around and latch onto the upper surface of the flange34.

Once the gasket42is assembled to the housing bracket, the skull cap24and bottom cover22can be assembled to the housing bracket30. As seen inFIG. 3, the skull cap24has an inwardly-extending flange70that fits under a protrusion72of the housing bracket30to interlock the skull cap24to the housing bracket30. Other attachments or fasteners may be used. The lower cover22includes a plurality of upwardly-extending projections or guide fingers74that extend through corresponding apertures76in the housing bracket30. This guides the skull cap24onto the lower cover22for assembly. Also, the lower cover22includes a plurality of attachment clips78that extend upwardly to flex and latch onto the housing bracket30. In one embodiment, the attachment clips78of the lower cover extend higher and beyond the height of the guide fingers74. The lower cover22may also include support ribs80that contact the outside of the hooks60to inhibit the hooks60from bending outward and out of engagement with the housing bracket30. The skull cap24may also include similar support ribs82that hold other hooks60of the gasket42. The ribs80of the lower cover22as well as the ribs82of the skull cap24trap the hooks to ensure they maintain an engagement with the housing bracket. This allows the gasket42to turn with the external side mirror20as the external side mirror folds or pivots. Thus, the gasket does not become visible upon turning of the mirror, such as if the gasket were molded or otherwise attached to the base assembly44. Also, the attachment of the gasket42via the hooks60being trapped by the ribs80,82is less expensive than overmolding a gasket directly onto the housing bracket30.

As shown inFIG. 4, the lower cover22and the skull cap24may not directly contact or engage one another. Instead, the gasket42may directly contact both the lower cover22and the skull cap24while covering the cutline gap between the base assembly44and the external side mirror20. In particular, the gasket42may cover and seal a gap between the lower edge49of the skull cap24and the base assembly44in an area where the lower cover22is not directly beneath the skull cap24, such as where the curved surface40of the skull cap24extends beyond the curved surface38of the lower cover22. When the mirror20pivots or rotates, the gasket42can slide along the surface of the base assembly44while still being removably mounted to the housing bracket30from beneath. This provides certain benefits over other potential designs, such as where a seal is overmolded over the base assembly, because such an overmold would become visible when the mirror is rotated due to the shape of the mirror.

FIG. 7shows an alternative embodiment of a gasket42′. The gasket42′ includes the same or similar features of the gasket42described with reference toFIGS. 2-6, except that the gasket42′ ofFIG. 7includes an optional strap or hook feature90. In particular, the strap90extends upward from two different locations at the second curved region54. The strap90loops over a corner of the flange34of the housing bracket30to which the gasket42′ attaches to. This feature aids in assembly. For example, an assembly operator can first wrap the hook90around the flange34to give a first attachment between the gasket42′ and the housing bracket30, providing leverage and allowing the operator to then more easily press the hooks60into engagement with the housing bracket30to further secure the gasket42′ to the housing bracket30without having to hold the gasket in place from beneath while doing so.