Spring secured mounting system

A spring clip for a vehicle for mounting a rearview device is disclosed. The spring clip comprises a base portion comprising a coupling surface, configured to interconnect the rearview device with the windshield, and a plurality of spring biased legs. Each of the spring biased legs forms an engagement profile having a continuous rounded profile and an internal engagement surface. The internal engagement surface forms a triangular assembly profile. The engagement profile is configured to slidably engage an interface profile of a bracket configured to interconnect the rearview device to the windshield.

BACKGROUND

The disclosure generally relates to a vehicle rearview device assembly. More particularly, the present disclosure relates to a mounting system for mounting an interior rearview device in the interior of a vehicle.

SUMMARY

One aspect of the present disclosure includes a rearview device mounting assembly configured for use with a vehicle. The mounting assembly comprises a spring clip having a plurality of spring biased legs. Each of the spring biased legs forms an engagement profile configured to couple to a subassembly comprising a rearview device and a plurality of spring biased legs. The assembly further comprises a bracket having an engagement surface and a plurality of lobes. The engagement surface is configured to couple to a windshield or indirectly through one or more intermediate components coupled to the windshield. The plurality of lobes extend outward from the engagement wall and correspond to each of the spring biased legs. The plurality of lobes form an interface profile configured to complement the engagement profile. The spring clip is configured to engage the bracket in a first assembly profile and rotationally engage the bracket in a second assembly profile to operably couple the spring clip to the bracket.

Another aspect of the present disclosure includes a spring clip for a vehicle for mounting a rearview device. The spring clip comprises a base portion comprising a mounting surface configured to interconnect the rearview device with the windshield and a plurality of spring biased legs. Each of the spring biased legs form an engagement profile having a continuous rounded profile and an internal engagement surface. The internal engagement surface forms a triangular assembly profile. The engagement profile is configured to slidably engage an interface profile of a bracket configured to interconnect the rearview device to a windshield.

Yet another aspect of the present disclosure includes a spring clip for a rearview device mounting assembly. The spring clip comprises a base portion forming at least one mounting opening, a plurality of spring biased legs, and an engagement surface. The engagement surface is configured to couple to a subassembly comprising a rearview device. Each of the spring biased legs forms an internal engagement surface. The spring clip is configured to receive a bracket in a first assembly profile and rotationally engage the bracket in a second assembly profile to operably couple the spring clip to the bracket.

The advantageous design introduced herein provides for an assembly configured to limit a plastic deformation of the spring clip. By limiting the plastic deformation, the assembly arrangement disclosed herein limits manufacturing costs by allowing for higher variance in various components of the assembly. This is accomplished, in part, by decreasing the spring constant of the spring clip legs. As is demonstrated in the detailed implementations that follow, the disclosure provides for a novel and beneficial assembly for supporting a rearview mirror.

DETAILED DESCRIPTION

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “clockwise,” “counter-clockwise,” “interior,” “exterior” and derivatives thereof shall relate to the arrangement of the elements introduced in reference toFIG. 1as viewed by an occupant of the vehicle shown. However, it is to be understood that the various elements of the assemblies illustrated may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Referring to the embodiment illustrated inFIGS. 1-2B, a rearview device mounting assembly8is illustrated in an exemplary implementation. The mounting assembly8includes a first subassembly and a second subassembly. The first subassembly is configured to engage and operably couple to the secondary subassembly. The first subassembly includes a spring clip10configured to secure a rearview device12to a bracket16disposed on a windshield14. The spring clip10includes a plurality of spring biased legs18extending from a base portion20. Each of the legs18includes an engagement profile22having a beveled engagement edge24and an internal engagement surface26. The engagement profile22forms a continuous rounded profile having a first continuous curved portion22aextending outward in a direction normal to a surface27of the base portion20and a second curved portion22bthat extends back toward the center of the base portion20proximate a distal end of the each of the legs18.

The first and second continuous curved portions22a,22bform a continuous curved portion corresponding to the continuous rounded profile. The continuous curved portion includes an enlarged continuous radius configured to prevent yield in each leg18of the spring clip10by enabling the first and second curved portions to deflect uniformly along the continuous curved portion. In this way, a spring force of each leg18may be maintained during an assembly operation of the spring clip10to the bracket16by limiting a plastic deformation of each of the legs18. Another benefit of this design is that the spring force of each of the legs18may be reduced while improving a resulting clamping force of the spring clip10to the bracket16. Yet another benefit of the design includes an increased tolerance in the manufacture of the spring clip10while maintaining the clamping force. For example, in an ideal configuration, a distal end of each of the plurality of legs18is approximately equidistant from the central axis extending from the center of the base portion20. However, the tolerance of the engagement profile22may vary such that a distal end portion of each of the legs18may vary in distance in relation to the center of the base portion20. The interaction of the spring clip10and the bracket16provides for tolerance of an increased variation in manufacture of the spring clip10and the bracket16while maintaining the clamping force.

In the current example and corresponding examples disclosed herein, the interaction of the engagement profile22of the spring clip10and a corresponding interface profile of the bracket16are configured to limit the deflection of each of the legs18and improve a uniformity of the deflection to reduce the yield in each of the legs18during an assembly operation. Some of the benefits provided by this disclosure include reduced cost and reduced spring stiffness of the spring clip10prior to an assembly operation resulting in an improved clamping force of the spring clip10to the bracket16after the assembly operation. The disclosure may further provide for improved life of the spring clip10through assembly and disassembly operations by reducing yield to maintain the improved clamping force.

Though the spring clip10and the bracket16are described as being respectively coupled to a first subassembly and a second subassembly, the arrangement of the spring clips and brackets discussed herein may be modified without departing from the spirit of the disclosure. For example, a bracket may be coupled to a first subassembly incorporating a rearview device and a spring clip may be coupled to a second subassembly coupled to the windshield14. The various implementations of the elements described herein may provide for a spring clip that undergoes minimal plastic deformation in assembly operation to provide enhanced pressure from a plurality of spring biased legs once assembled. The various implementations discussed herein provide for a novel assembly interface that provides for a decrease in cost by allowing increased manufacturing variation in the spring clip and the bracket without decreasing the effectiveness of the interface.

With reference toFIGS. 2A-2B, the internal engagement surface26of each of the legs18forms a spring biased portion28configured to engage and operably couple to an engagement edge32e—top edge of wall32of the bracket16. In the illustrated embodiments, the engagement wall30of the bracket16forms a tri-lobe button including a plurality of lobes32extending outward from the engagement wall30. Each of the lobes32is formed having a plurality of rounded corners34and rounded ribs36. The rounded corners34of each of the lobes32form an interface profile38configured to rotatably engage the internal engagement surface26of each of the legs18of the spring clip10. When rotated in a mating formation, each of the legs18engages each of the rounded ribs36of the lobes32causing each of the spring biased portions28to apply pressure to each of the lobes32at edge32e. The spring clip10may lock into a mounted position as the internal engagement surface26of each legs18aligns with each lobe32at edge32e.

The corresponding surfaces and rotating interaction of the bracket16and the spring clip10provide for an efficient locking assembly that minimizes the deflection of the spring clip10while being assembled to the bracket16. This advantageous design provides for minimal plastic deformation allowing a clamping force of the spring clip10applied to the bracket16to be maximized for a given deflection of each of the legs18of the spring clip10in the mounted position. Limiting the plastic deformation of the spring clip10further allows for lower cost in manufacturing and higher variance in the spring clip10while maintaining a requisite spring force for coupling the spring clip to the bracket for various implementations.

Referring to the embodiment illustrated inFIG. 1, the reference numeral8generally designates a rearview device mounting assembly for use in a vehicle40. The rearview device mounting assembly8is configured to attach to the windshield14and includes the first subassembly and the second subassembly. The first subassembly includes the rearview device12shown mounted to the windshield14and further includes a rearview device mount46, sometimes also known as a “channel mount” or “die cast piece.” The spring clip10is operably coupled to the mount46and one or more intermediate components including a mounting plate may be disposed between the mount46and the spring clip10. The rearview device mounting assembly8of the present disclosure may be used with a variety of mounts which are configured for engagement with a variety of rearview devices22including prism-type mirrors, electrochromic mirrors, and camera displays.

During an assembly operation, the bracket16may initially be secured to the windshield14directly or through one or more intermediate components of the second subassembly. Illustrated here in an assembled form, the first subassembly including spring clip10is operably coupled to the bracket16. The spring clip10is further operably coupled to the mount46and is received over the bracket16. With the second subassembly secured to the windshield14and the first subassembly secured to the second subassembly, the rearview device mounting assembly8adjustably supports the rearview device12in cantilevered fashion such that the device12projects into a passenger compartment of the vehicle40for use by the operator of the vehicle. The configuration of the rearview device mounting assembly8is arranged such that an assembly operation may be undertaken to consistently and securely attach the spring clip10to the bracket16while minimizing the plastic deformation of the spring clip10.

Referring still to the embodiment ofFIGS. 2A and 2B, the spring clip10is configured to secure the rearview device12to the bracket16. The base portion20of the spring clip10further includes a coupling surface48configured to abut the mount46as discussed inFIG. 4or an intermediate mounting plate. The spring clip10may be secured to the mount46with a fastener by engaging the spring clip10through a mounting opening50located centrally in the base portion20. A center of the mounting opening50may define a central axis extending approximately from the center of the base portion27. In some implementations, the mounting opening may be implemented as a plurality of openings configured to receive a plurality of fasteners. An exterior contour54of the spring clip10may further be configured to engage a pocket of the mount46to secure the spring clip.

The bracket16further includes an engagement surface56and a first exterior profile58. The engagement surface56may be configured to attach to one or more intermediate components of the second subassembly to secure the bracket16to the windshield14. The first exterior profile58is configured in a rounded shape that includes a plurality of notches60, in this example two notches. Each of the notches60may further be configured to align with a corresponding portion of the one or more intermediate components to align or secure the bracket16to the one or more intermediate components.

A second exterior profile62extends around the bracket16between a front surface64and the engagement wall30. The second exterior profile62is also configured in a rounded shape and is aligned coaxially with the first exterior profile58. A cylindrical opening66is further disposed coaxially with the first exterior profile58and extends from the engagement surface56to an optional cone-shaped opening52. The engagement wall30has a profile having a first triangular assembly profile68and a second triangular assembly profile70. The first triangular assembly profile68is configured to align with the internal engagement surfaces26of each of the plurality of legs18, in this example the three legs having a corresponding triangular shape. The second triangular assembly profile70is configured to rotatably engage the legs18by applying pressure from each of the lobes32in response to a rotational force applied to the spring clip10. Upon rotation into the mounted position, each of the legs18may align with each of the lobes32to secure the first subassembly including the spring clip10to the second subassembly including the bracket16.

Referring to the embodiment ofFIGS. 3A and 3B, detailed perspective views of a spring clip82and a bracket84are shown. The spring clip82and the bracket84may demonstrate additional features and elements that may be implemented alone or in combination with the elements described in reference to the spring clip10and the bracket16of the mounting assembly8. The spring clip82includes a plurality of spring biased legs86, in this example three legs, extending from a base portion87. Each of the legs86includes an engagement profile88having a beveled engagement edge90. Each of the legs86further forms an internal engagement surface94. The engagement profile88includes a first curved portion88aextending outward along a first radius in a direction normal to a surface95of the base portion87. A straight portion88bmay extend from a distal end portion of the first curved portion88aalong the direct normal to the surface95. A second curved portion88cmay further extend along a second radius from a distal end portion of the straight portion88band extend back toward the center of the base portion87proximate to a distal end of the each of the legs86.

Additionally, as shown inFIG. 3A, a tapered portion is formed by each of the legs86extending from the first curved portion88ato the second curved portion88c. In this configuration, the spring force of each of the legs is significantly maintained along the tapered portion. In this way, the spring clip82further provides for decreased rotational force required during assembly compared to conventional spring clips. The tapered portion further provides for decreased yield in the spring clip82to improve the life of the assembly described herein.

The internal engagement surface94forms a spring biased portion96configured to engage and operably couple to an engagement wall98of the bracket84. The engagement wall98of the bracket84may form a tri-lobe button including a plurality of lobes100extending outward from the engagement wall98. Each of the lobes100is formed having a plurality of rounded corners102and fileted ribs104. The fileted ribs104extend outward from the engagement wall and form a narrow portion106proximate to a distal end portion of each of the lobes100. The narrow portion106and the rounded corners102of each of the lobes100form an interface profile configured to rotatably engage the beveled engagement edge90of each of the internal engagement surfaces94.

An interaction of each of the lobes100of the bracket84may cause each of the spring biased portions96to lift in the direction normal to the surface95and radially from the centerline axis due to the a force being applied by the fileted ribs104during the rotational engagement of each of the lobes100. In this way, a spring force of each leg86may be maintained during an assembly operation of the spring clip82to the bracket84by limiting a plastic deformation of each of the legs86. Another benefit of this design is that the spring force of each of the legs86may be reduced while improving a resulting clamping force of the spring clip82to the bracket84. Yet another benefit of the disclosure includes an increased tolerance in the manufacture of the spring clip82while maintaining the clamping force. For example, the tolerance of the engagement profile88including the first and second curved portions88a,88cand the straight portion88bmay vary such that a distal end portion of each of the legs86may be may vary in distance in relation to the center of the base portion87. The interaction of the spring clip82and the bracket84provides for tolerance of an increased variation in manufacture of the spring clip while maintaining the clamping force.

In this example and corresponding examples disclosed herein, the interaction of the engagement profile88of the spring clip82and the interface profile of the bracket84are configured to limit the deflection of each of the legs86and improve a uniformity of the deflection to reduce the yield in each of the legs86during an assembly operation. Some of the benefits provided by this disclosure include reduced cost and reduced spring stiffness of the spring clip82prior to an assembly operation resulting in an improved clamping force of the spring clip82to the bracket84after the assembly operation. The improved clamping force may be a result of limited plastic deformation between a spring clip (e.g.12,82) and a bracket (e.g.16,84) during an assembly operation. Reducing plastic deformation via the various aspects of the spring clip and the bracket provides for improved life of the spring clip through assembly and disassembly operations by reducing yield to maintain the improved clamping force.

The spring clip82is configured to secure a rearview device, for example the rearview device12, by rotationally engaging the bracket84. Similar to the implementation introduced in reference toFIGS. 2A and 2B, the spring clip82and the bracket84may be implemented as respective components in a first subassembly and a second subassembly of a mounting assembly (e.g. mounting assembly8). The base portion87of the spring clip82further includes a coupling surface110configured to abut a mount, for example the mount46, or an intermediate mounting plate. The spring clip82may be secured to the mount46by a fastener by engaging the spring clip82through a mounting opening112located centrally in the base portion87. In some implementations, a mounting opening may be implemented as a plurality of openings in the base portion87configured to receive a plurality of fasteners. An exterior contour116of the spring clip10may further be configured to engage a pocket of the mount46to secure the spring clip to the mount46.

The bracket84further includes an engagement surface118, a front surface119, and a first exterior profile120. The engagement surface118may be configured to attach to one or more intermediate components of the second subassembly to secure the bracket84to the windshield14. The first exterior profile120is configured in a rounded shape that includes at least one notches122, in this example two notches122. Each of the notches122may be configured to align with a corresponding portion of the one or more intermediate components to align or secure the bracket84to the one or more intermediate components.

A cylindrical opening124is disposed coaxially with the first exterior profile120and extends from the engagement surface118to a cone-shaped opening114. The engagement wall98includes a profile having a first triangular assembly profile126and a second triangular assembly profile128. The first triangular assembly profile126is configured to align with the internal engagement surfaces94of each of the plurality of legs86, in this example the three legs86having a corresponding triangular shape. The second triangular assembly profile128is configured to rotatably engage the legs86by applying pressure from each of the lobes100in response to a rotational force applied to the spring clip82. Upon rotation into the mounted position, each of the legs86may align with each of the lobes100to secure a first subassembly including the spring clip82to a second subassembly including the bracket84.

The corresponding surfaces and rotating interaction of the bracket84and the spring clip82provide for an efficient locking assembly that minimizes the deflection of the spring clip82while being assembled to the bracket84. This advantageous design provides for minimal plastic deformation allowing a clamping force of the spring clip82applied to the bracket84to be maximized for a given deflection of each of the legs86of the spring clip82in the mounted position. Limiting the plastic deformation of the spring clip82further allows for lower cost in manufacturing and higher variance in manufacturing the spring clip82and other similar spring biased clips introduced herein.

Referring now toFIG. 4, a cutout portion140of the first subassembly is shown including a spring clip142disposed in a mount143. The mount143may be similar to the mount46. In this illustrated embodiment, the spring clip142is shown received by the mount143. A first fastener144and a second fastener146are disposed in a first mounting opening and a second mounting opening of the spring clip142and are further received by a first attachment cavity and a second attachment cavity of the mount143. A plurality of legs148of the spring clip142extend outward from a pocket150formed by the mount46. In this configuration, spring biased portions152of each of the plurality of legs148extends out of the pocket150such that an engagement profile154is positioned to engage an interface profile of a plurality of lobes of a bracket, for example the brackets16,84.

A perimeter wall156of the mount143forms an exterior surface158. A plurality of posts160are formed parallel to the exterior surface158and extend outward from the mount143. In the assembled configuration, the posts160also extend parallel to a direction normal to a surface162of a base portion of the spring clip142. Each of the posts160includes a contact surface166configured to frictionally engage a front surface of a bracket, for example the front surfaces64,119. An assembly operation of the first subassembly begins by aligning the spring clip142with the front surface of the bracket such that the contact surfaces166of the posts160contact the front surface of the bracket. Once aligned, the first subassembly is rotated such that the interface profile of the plurality of lobes of the bracket may cause a deflection in each of the spring biased portions152of the legs148.

The rotation of the first subassembly may continue until each of the lobes of the bracket is aligned with each of the plurality of legs148. A locking detent168may further interact with a locking portion of the second subassembly, for example the one or more intermediate components coupled to the bracket. In this way, the spring clip142and the bracket may be locked in an assembled orientation to ensure that the assembly remains coupled to support a rearview device. The assembly operation described above limits the plastic deformation of the spring clip142and allows for lower cost in manufacturing the assembly. Limiting the plastic deformation may provide for lower cost materials to be used in manufacturing the spring clips10,82,142; the brackets16,84; and various combinations and variations as discussed herein.