Single shell, double view mirror for vehicles

A single shell side-view mirror assembly is disclosed which provides improved aerodynamic features and improved vibrational resistance characterized by an aerodynamically domed shell structure, interchangeable mirror elements, an electrically activated vibration dampening element and a static vibration dampening elements.

BACKGROUND OF THE INVENTION

The present invention generally relates to safety devices for vehicles and, in particular, to a side-view mirror assembly for a vehicle in the form of a motorized, single shell, dual view, side-view mirror.

Side-view mirrors for large vehicles such as school buses, transit buses and trucks present special design challenges. Specifically, because of the height and size of the vehicles, it is necessary to provide an ample viewing area for a long distance along the side of the vehicle, as well as a view which is directed more toward the ground. Conventionally, separate mirror elements have been provided for these diverse viewing requirements. For example, one mirror element has been traditionally mounted to provide a unique field of view by way of a large flat mirror surface and another mirror element has been provided with a convex surface to provide a wider field of view. These prior art mirror elements, while serving their intended functions, also have the unintended and undesired result that they obscure a substantial field of view forward of the mirror assemblies.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a more effective, improved mirror assembly for vehicles such as school buses, transit buses, trucks and the like.

Another object of the invention is to provide a mirror assembly for vehicles which is diverse and easier to use.

Another object of the present invention is to provide a mirror assembly with superior vibration damping features and aerodynamic features for an improved field of view.

In accordance with the present invention, a vehicular side-view mirror assembly has a shell housing; a first and a second mounting element disposed in the shell housing; a first mirror unit having a first side-view mirror, where the first mirror unit is connected to the first mounting element and where the first mirror unit is independently adjustable. The side-view mirror assembly also has a second mirror unit having a second side-view mirror, where the second mirror unit is connected to the second mounting element and where the second mirror unit is independently adjustable. Still further, the mirror assembly has a support member for coupling the shell housing to the vehicle.

The foregoing and numerous other objects of the invention are realized with a mirror assembly which is described below by reference to the drawings and detailed description which follows.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

With reference toFIG. 1, the mirror assembly1of the present invention is mounted to a school bus and provides an ample field of view along the side of the vehicle as well as a view which is directed more towards the ground.FIG. 2shows a mirror assembly1which is not mounted to a vehicle. The mirror assembly1comprises a shell housing10, a mirror pole20and a hinge member30. The shell housing10has a substantially rectangularly shaped opening14and interior space and contains a rectangularly shaped first mirror unit16and a convex-surfaced second mirror unit18. An electrical cable section (or harness)35extends from the hinge member30for providing electrical connections between a motor control switch (not shown) and the motors (not shown) contained in the first mirror unit16and the second mirror unit18.

The exploded view (FIG. 3) of the mirror assembly1of the present invention shows first and second mirror units16,18which are mounted in the shell housing10such that the reflecting surfaces of the mirrors60,80lie substantially parallel to the plane of the opening14. Mounting hole11provides an opening for the mirror pole20to enter the shell housing10. A grommet22is disposed in the mounting hole11and prevents moisture, dirt and the like from entering the shell housing10through the mounting hole11. The mirror pole20comprises a first support arm26and a second support arm28each having a mounting hole21on its distal end.

Note that the mirror assembly1may be mounted on a vehicle body such that the shell housing10is below the hinge member30thereby being in the opposite vertical orientation from that shown inFIGS. 2 and 3. When the mirror assembly1is in such opposite, vertical orientation, the grommet22also prevents water, dirt of the like from entering the shell housing10through the mounting hole11.

With reference toFIG. 4, the shell housing10comprises a mounting hole11, clamping plates19, and longitudinal reinforcing ribs15for accepting the mirror pole20and operatively connecting the shell housing10and the mirror pole20. The mirror pole20is disposed through the mounting hole11and under the clamping plates19. The longitudinal reinforcing ribs15are disposed along the wall of the shell housing10to provide structural reinforcement for clamping the mirror pole20to the shell housing10. The height of the outermost longitudinal reinforcing ribs15, with respect to the wall of the shell housing10, are higher than the innermost longitudinal reinforcing ribs15thereby defining an arcuate cross section (or resting surface) for snugly engaging the mirror pole20. Orthogonal reinforcing ribs15aare disposed near the clamping plates19to provide additional structural support. The clamping plates19are securely engaged against the mirror pole20via rear entry bolts19a.

As best seen inFIG. 4a, the rear entry bolts9aare tightened from the rear (windward) side of the shell housing10. The shell housing10is provided with countersunk holes which accept the rear entry bolts19aand permit sub-flush disposition of the bolts19a. Further, rubber covers (not shown) are disposed over the countersunk holes to provide a smooth and flush finish on the windward side of the shell housing10which adds to the aerodynamic design of the shell housing10.

As best seen inFIG. 2, the housing shell10is aerodynamically shaped. Specifically, the forward surface of the shell housing10is narrow and tapers outward toward the opening14, which accepts the mirror units16,18. Therefore, wind resistance and vibrations caused by wind velocity are reduced and the tendency for the shell housing10to shift or turn as a result of torsional forces developed on the mirror pole20from wind are mitigated.

The shell housing10further comprises a cover12awhich snugly fits over the maintenance opening12. As will be discussed in more detail below, the maintenance opening12provides access to the cabling between various electrical components of the mirror assembly1. The cover12afits flush with respect to the surface of the shell housing10thereby maintaining the aerodynamic features of the mirror assembly1. Furthermore, the cover12provides a surface for the display of a company name, trademark or other indicia, which display can be easily changed without requiring re-stenciling of the shell housing10of the mirror assembly1. Rather, the simple and inexpensive step of replacing the cover12awith a new cover displaying the new indicia completes the process.

Referring toFIG. 4, the shell housing10is provided with oppositely disposed supporting ribs17which extend along the wall of the shell housing10and terminate on end surfaces of the shell housing10. Integral with the supporting ribs17are long standoffs13and short standoffs13a. Four long standoffs13are disposed at each of the ends of the shell housing10. Ten short standoffs13aare disposed between the long standoffs13and are also integral to the support ribs17. As will be discussed below, the long standoffs13and the short standoffs13aprovide a supporting structure for the first and second mirror units16,18.

With reference toFIG. 5, the mirror pole20and the hinge member30are shown. The hinge member30comprises a first housing member32and a second housing member34which fit snugly around the first and second support arms26,28. As shown inFIG. 5a, hinge plate36operatively connects to the first housing member32via a nut and precision bolt31and anti-scoring washers37.

First and second support arms26,28which extend from the mirror pole20are insertable into the hinge member30by way of arcuate recesses in the first and second housing members32,34of the hinge member30. More specifically, the second housing member34is removable from the first housing member32thereby exposing the arcuate recesses for engaging the first and second support arms26,28. The first and second support arms26,28are inserted into the arcuate recess of the first housing member32and the mounting holes21, disposed on the distal ends of first and second support arms26,28, are lined up with the holes21aof the first and second housing members32,34. Allen-type bolts are inserted into the holes21awhich clamp the first and second housing members32and34together and further engage the first and second support arms26,28of the mirror pole20.

The second housing member34of the hinge member30operatively connects to the hinge plate36via a nut and a precision bolt31(FIG. 5a), anti-scoring washers37and a precision bore40. Thus, the precision bolt31passing through the first housing member32, the anti-scoring washers37and the precision bore40of the hinge plate36enable the hinge plate36to swivel with respect to the first housing member32. Accordingly, the mirror assembly1can swivel with respect to the vehicle to which it is mounted if sufficient force is exerted in torsional relation to the hinge member30.

Further, anti-scoring washers37mitigate any deterioration in the precision dimensions of the hinge plate36and, in particular, the precision bore40when the hinge plate36is swiveled in relation to the first housing member32. It is preferred that anti-scoring washers37be fabricated from a softer material than the hinge plate6. For example, when the hinge plate6is formed of steel, it is preferred that the anti-scoring washers37be fabricated from brass.

The first housing member32and the hinge plate36are provided with a detent means for fixing the relative position of the hinge plate36with respect to the first housing member32. Specifically, the first housing member32is provided with a cavity42. Cavity42contains a spring (not shown) and a piston44disposed forward of the spring and extending beyond the surface of the first housing member32. As best seen inFIG. 5b, the piston44comprises a channel45extending diametrically across the top surface of the piston44. The surface of the first housing member32comprises a cooperating notch46with the channel45in the piston44for engagement with a detent member33. When the hinge plate36is in position, with the precision bolt31passing through the first housing member32and the precision bore40of the hinge plate36, the detent member33operatively engages both the channel45and an inward detent38of the hinge plate36. The notch46in the surface of the first housing member32provides relief for accepting the detent member33so that the detent member does not contact the first housing member32. Thus, the hinge plate36is held in a fixed relationship with respect to the first housing member32and, accordingly, the mirror assembly1is held in a fixed relationship with respect to the vehicle to which it is attached.

However, sufficient torsional force on the hinge plate36with respect to the first housing member32will force the piston44inwardly and release the detent member33from the channel45and the inward detent38, thereby permitting swingable movement of the mirror pole20with respect to the hinge plate36. When the hinge plate36is rotated sufficiently with respect to the first housing member32, the outward detent39will engage the channel45of the piston44and the hinge plate36will again be fixed in position relative to the first housing member32, but at a different position. The cooperation of the outward detent39and the channel45of the piston44define a maximum rotational position to prevent vehicle damage when the mirror assembly1is rotated with respect to the vehicle, for example, when an object is struck while in motion.

Moreover, the precise sizing of the precision bolt31and the precision bore40coupled with the high force provided by the spring, the channel45, the detent member33, and the inward detent38, minimizes vibrations developed during vehicular travel, which vibrations tend to propagate through the hinge plate36, the hinge member30and the mirror pole20to the first and second mirror units16,18.

Furthermore, for large vehicles, the first and second support arms26,28are extended and protrude much further from the arcuate recesses of the first and second housing members32,34. To mitigate against vibrations developing in the support arms26and28, a core material23is added to the inside volume of the first and second support arms26,28and the mirror pole20. It is preferred that the core material23is of a dissimilar metal than that of the mirror pole20and the first and second support arms26,28because experiments have shown that vibrations are reduced when dissimilar metals are used. Specifically, it is preferred that the mirror pole20and the first and second support arms26,28are fabricated from steel tubing and the core material23is fabricated from aluminum tubing.

The novel, sturdy and aerodynamic features of the shell housing10, the mirror pole20and the hinge member30, described above, enable one-point connection of the mirror assembly1to the vehicle via hinge plate36without sacrificing vibration dampening characteristics.

With reference toFIG. 6, the rectangularly shaped first mirror unit16is shown in greater detail. The first mirror unit16comprises a flat mirror60, a flat mounting plate61, a cup65and a swivel mechanism66. The swivel mechanism66moves in relationship to the cup65. The cup65is dome shaped on the bottom and operatively engages the dome shaped member of the swivel mechanism66which provides a swivelling motion in both horizontal and vertical directions. Gearing and swivel members (not shown) are connected to the cup65and to two motors (not shown) of the swivel mechanism66to enable motorized swiveling of the cup65with respect to the swivel mechanism66in a manner well known in the art. A boot (not shown) covers the critical elements of the swivel mechanism66and the cup65to prevent debris from deteriorating the operation of the first mirror unit16.

The flat mirror60is disposed on a flat mounting plate61and secured at its edges by a long snap62and a short snap63. Relative ease of installation of the flat mirror60onto the flat mounting plate61is achieved by first inserting one edge of flat mirror60under one of the long snap62and the short snap63and then pressing the other end of flat mirror60under the remaining snap to obtain secure engagement of the flat mirror60to the flat mounting plate61. It is preferred that one edge of the flat mirror60is first placed under the long snap62and then the other end of flat mirror60is snapped under short snap63.

The ease with which the flat mirror60is secured to, and removed from, the flat mounting plate61enables field replaceability and retrofitability of the flat mirror60, for example, when the flat mirror60is accidentally broken.

Vibration tabs64extend somewhat above the plane of the flat mounting plate61and are elastically biased to engage the rear surface of the flat mirror60when the mirror is engaged under the long snap62and the short snap63. The force exerted by the vibration tabs64to the rear surface of the flat mirror60prevents vibrations in the flat mirror60when the vehicle is in motion or when vibrations are transmitted to the first mirror unit16from other sources such as, for example, from the engine of the vehicle.

With reference toFIG. 6a, an electro-mechanical solenoid76may be coupled to the mounting plate61, which solenoid76comprises a core78and a spring (not shown). The mounting plate61is provided with a hole so that the core78projects out of the hole. The spring forces the core78outwardly from the solenoid body when the solenoid76is not energized. When the solenoid is energized, the core78moves inwardly and overcomes the force exerted by the spring, which spring tends to keep the core78in the outward position.

The solenoid76is positioned such that the core78contacts the inside surface of the shell housing10when the solenoid is not energized and the spring forces the core78into its outward position. Therefore, when the solenoid is not energized, vibrations of the flat mounting plate61with respect to the shell housing10are damped.

However, when it is desired that the position of the first mirror unit16be changed via the motors of the swivel mechanism66, the solenoid76is concurrently energized with the motors (via the motor control switch) such that the core78is drawn inwardly and away from the inside surface of the shell housing10thus enabling free movement of the flat plate61with respect to the swivel mechanism66. Further, when the first mirror unit16has reached the desired position and the motors of the swivel mechanism66are deactivated, the solenoid76is also deactivated and the core78returns to its resting position against the inside surface of the shell housing10.

With reference toFIG. 7, a more detailed drawing of the convex-surfaced second mirror unit18is shown. The second mirror unit18comprises a convex mirror80, a convex mounting plate81, a cup85and a swivel mechanism86. The swivel mechanism86comprises two motors (not shown) which are coupled via gearing to the cup85to enable motorized swiveling of the cup with respect to the swivel mechanism86. The convex mounting plate81comprises a long snap82, a short snap83, and vibration tabs84. The swivel mechanism86may optionally comprise an electro-mechanical solenoid96, as shown inFIG. 7a, where the solenoid comprises a core98and a spring (not shown). The operation of the motorized features and anti-vibration features of the convex-surfaced second mirror unit18are substantially similar to the same features of the rectangularly shaped first mirror unit16and, therefore, a detailed recitation of the interconnection and operation of the aforementioned elements of the second mirror unit18is omitted.

With reference toFIGS. 3,4,6and7, a description of the interconnections between the first and second mirror units16,18, and the shell housing10will now be described. The first mirror unit16may be positioned away from the mounting hole11towards one end of the shell housing10and the second mirror unit18may be positioned near the mounting hole11and below the first mirror unit16as shown in FIG.3. However, when the end user is desirous to have the second mirror unit18positioned away from the mounting hole11towards one end of the shell housing10and the first mirror unit16positioned towards the mounting hole11and below the second mirror unit18, the mirror assembly1is easily adapted.

For example, in some instances, attachment of the mirror assembly1to the vehicle requires that the hinge plate36be positioned above the shell housing10, where the mounting hole11would be in a upward vertical orientation. In such a situation, the end user of the mirror assembly1may desire to have the first mirror unit16positioned above the second mirror unit18because of the unique optical characteristics of a convex mirror versus a flat mirror. Typically, mounting the mirror assembly1with the hinge plate36above the shell housing10would result in the convex-surfaced second mirror unit18being disposed above the rectangularly shaped first mirror unit16. However, with the novel configuration of the shell housing10and the first and second mirror units16,18of the present invention, an inversely mounted mirror assembly1(where the hinge plate36is mounted on the vehicle above the shell housing10) would not necessarily result in the first mirror unit16being disposed beneath the second mirror unit18. Indeed, the first and second mirror units16,18may be readily interchanged and disposed at either end of shell housing10.

To accommodate the above-described versatility (FIGS.8and9), the long standoffs13are positioned at both ends of the shell housing10and operatively connect to the swivel mechanism86of the convex-surfaced second mirror unit18via connecting plate93when the second mirror unit18is disposed at one of the two ends of the shell housing10. The short standoffs13a, which are disposed between long standoffs13along the supporting ribs17, operatively connect with the swivel mechanism66of the rectangularly shaped first mirror unit16via the connecting plate73when the first mirror unit16is disposed at one of the ends of the shell housing10. The longs standoffs13and short standoffs13aare sized such that the long standoffs13do not interfere with the connecting plate73of the rectangularly shaped first mirror unit16, irrespective of which end of the shell housing10the first mirror unit16is disposed. Furthermore, if the end user is desirous of a single mirror unit rather than the first and second mirror units16,18as discussed hereinabove, a larger mounting plate (of the flat-type or convex-type) may be integrated with a stationary cup and a swivel mechanism of the type described for the larger, rectangularly shaped first mirror unit16. In such a situation, only the short standoffs13awould be utilized to fasten the coupling plate of the single mirror unit to the shell housing10.

The shell housing10, the flat mounting plate61, the cup65, the swivel mechanism66, the connecting plate73, the convex mounting plate81, the cup85, the swivel mechanism86and the connecting plate93may be manufactured from suitable plastics, metals, composite materials or the like. It is preferred that the above-listed elements be manufactured from suitable plastics. The mirror pole20and the hinge member30may also be manufactured from suitable plastics, metals, composite materials or the like; however, it is preferred that these elements be manufactured from suitable metals. As described above, it is most preferred that mirror pole20and the first and second support arms26,28be manufactured from steel and the core material23be manufactured from aluminum.

Installation of the mirror assembly1onto a vehicle requires cabling from the motor control switch (typically mounted inside the vehicle) to the respective motors of the swivel mechanism66and the swivel mechanism86. Therefore, the electrical conductors of the electrical cables required to interconnect the electrical components of the mirror assembly1are bundled in heat shrinkable sleeves for stiffening and protecting the electrical conductors. The cable section35extends from an opening in the second housing member34through and to the opposite end of the mirror pole20. The end of the cable35which extends from the bottom of hinge member30is electrically and mechanically connected to the electrical conductors of the motor control switch. The other end of the cable section35terminates near the maintenance opening12of the shell housing10when the mirror pole20is inserted through the mounting hole11. A cable section35a(as shown inFIG. 3) operatively connects to the respective motors of the first mirror unit16and the second mirror unit18and terminates near the maintenance opening12when the mirror units are installed in the shell housing10. Therefore, after installation of both the mirror pole20and the first and second mirror units16,18the electrical connection of the cable section35and the cable section35amay be conveniently made through the maintenance opening12.

Conversely, in mirror units of the prior art, cable connections are awkwardly made through a mounting hole (similar to mounting hole11) or such connections are made before a mirror unit is installed into a housing.

Advantageously, the cover12aof the present invention, which seals the maintenance opening12, serves the dual purpose of sealing the shell housing10after required cable connections are made and provides a convenient and interchangeable surface for displaying a company name, trademark or other indicia.

Still further, the invention contemplates providing a heating element (not shown) inside the shell housing10to maintain the mirrors at a desired temperature, so as to prevent fogging or icing of the mirror elements60,80.

The mirror assembly1of the present invention can be constructed such that the shell housing10has a width of approximately 7½ inches and a height of approximately 13-14 inches. The depth of the shell housing10tapers toward the center, at its deepest point measuring approximately 3-4 inches.

The larger, first mirror unit16may have a width of approximately 6 to 7 inches and a height of approximately 9-10 inches. The smaller, second mirror unit18has a height of approximately 4 to 4½ inches and a width of approximately 7 inches. These dimensions are significant in that they have been selected to reduce the size of the blind spot in front of the mirror assembly while providing a more than sufficient rearward field of view, in full compliance with regulatory requirements.

Significant, advantageous and important benefits ensue from the present invention in that it is directly applicable to and mountable on school buses. It is self evident as well as understood that society and government are particularly anxious to provide special safety features for our youngsters during their travels to and from school. School buses are often operated by different drivers and it is imperative that each driver carefully position his/her school bus mirrors to ensure optimal viewing of the movement of both pupils and vehicles in and about the school bus. The present invention aids in achieving that objective in that it allows easy and rapid adjustment of mirrors which plays a significant roll in reducing accidents and protecting our youngsters.