REARVIEW MIRROR ASSEMBLY WITH MOUNTING ARRANGEMENT INCLUDING INTEGRALLY MOLDED DUAL AXIS PIVOT MEANS

Abstract: A rearview mirror assembly (10) including an exteriorly convex shell (12) has a concave interior opening rearwardly when the shell is mounted on the side of a vehicle. A power operated assembly (14) is fixed secured to the shell (12) for mounting and moving a mirror assembly (16) for pivotal movement within the open rear of the shell about first and second intersecting pivotal axes normal to one another. The power operated assembly (14) includes a molded plastics member (20) of a size to fit within the concave interior of the shell (12) so as to extend inwardly of and generally across the open rear thereof. The plastics member (20) has spaced portions (22,24) fixedly secured with spaced portions (26,28) of the concave interior of the shell so that the molded plastics member serves as a strengthening strut for the open rear of the shell. The plastics member (20) has a dual axis pivot element (54) molded integrally on the central portion thereof which extends rearwardly therefrom and integral first and second surfaces (62) for engaging and supporting one fore and aft half of first and second power operated moving mechanisms (18) respectively of the power operated assembly. The other fore and aft half of the first and second power operated moving mechanisms (18) respectively is supported by a pair of separate substantially identical casing members (60).

Description: The present invention relates to rearview mirror assemblies, and more particularly to power operated rearview mirror assemblies arranged to be attached to an exterior side of a vehicle. US-A-4 482 211 discloses a rearview mirror assembly arranged to be attached to an exterior side of a vehicle, said assembly comprising an exteriorly convex shell having a concave interior opening rearwardly when said shell is mounted on the side of a vehicle, a mirror case, mounting means secured to said shell and comprising dual axis pivot means, and means carried by said mirror case in cooperating relation with said dual axis pivot means for mounting said mirror case within the open rear of said shell for pivotal movement about first and second intersecting pivotal axes normal to one another, a first power operated moving mechanism carried by said mounting means including a first reversible electric motor and a first rearwardly extending motion transmitting member movable rearwardly in response to the rotation of said first motor in one direction and forwardly in response to the rotation of said first motor in an opposite direction, means connecting the rearwardly extending end of said first motion transmitting member with said mirror case along said first axis in spaced relation to said second axis so that the forward and rearward movements of said first motion transmitting member moves said mirror case in opposite directions about said second axis, a second power operated moving mechanism carried by said mounting means including a second reversible electric motor and a second rearwardly extending motion transmitting member movable rearwardly in response to the rotation of said second motor in said one direction and forwardly in response to the rotation of said second motor in an opposite direction, means connecting the rearwardly extending end of said second motion transmitting member with said mirror case along said second axis in spaced relation to said first axis so that the forward and rearward movements of said second motion transmitting member moves said mirror case in opposite directions about said first axis. The known assembly has a power unit fitted within the shell and comprised of two cooperating housing parts. The known unit can be made sufficiently compact that it can be used in mounting shells having a great variety of different shapes and sizes. However, particularly where relatively large mounting shells are to be utilised, such as in truck vehicles or the like, the weight and strength of the mounting shell become significant cost factors in the entire assembly. It is desirable to make the shell with a wall thickness which is minimised to thereby minimise material with the resultant savings in cost and weight. It is an object of the present invention to provide a rearview mirror assembly which is able to operate reliably with minimum material and minimum weight. According to the present invention a rearview mirror assembly of the type defined above is characterised in that said mounting means comprises a moulded plastic member of a size to fit within the concave interior of said shell so as to extend inwardly of, and generally across, the open rear thereof, in that means are provided for fixedly securing spaced portions of said moulded plastic member with spaced portions of concave interior of said shell so that said moulded plastics member serves as a strengthening strut for the open rear of said shell, in that said dual axis pivot means comprises a dual axis pivot element moulded integrally on the central portion of said moulded plastic member and extending rearwardly therefrom, in that said moulded plastic member has integral first and second one half mounting surface means for engaging and supporting one fore and aft half of said first and second power operated moving mechanisms respectively, and in that a pair of separate substantially identically configured first and second casing members are fixed to said moulded plastic member and have first and second other half mounting surface means respectively for engaging and supporting the other fore and aft half of said first and second power operated moving mechanisms respectively. With the present invention, a range of customised plastic member can be provided to accommodate the full range of shell sizes in such a way that each serves as a strengthening strut for the open rear of the shell, thus enabling the same to be formed of less material and less wall thickness. At the same time, the pair of casing members which are substantially identical and hence require less tooling for production, can be used with all of the moulded plastic members throughout the size range. The result is an efficient use of the material which provides for adequate strength. The present invention thus provides a rearview mirror assembly which is simple in construction, effective in operation, and economical to manufacture. An embodiment of the present invention will hereinafter be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a rear elevational view of a rearview mirror assembly embodying the principles of the present invention, with the mirror case and mirror removed for purposes of clear illustration; Figure 2 is an enlarged fragmentary sectional view taken along the line 2-2 of Figure 1; Figure 3 is an enlarged fragmentary sectional view taken along the line 3-3 of Figure 1; Figure 4 is an enlarged fragmentary sectional view of the mirror assembly including the mirror case and mirror taken along the line 4-4 of Figure 1; and Figure 5 is an enlarged fragmentary sectional view taken along the line 5-5 of Figure 1. Mode for Carrying out the Invention Referring now more particularly to the drawings, there is shown therein a rearview mirror assembly, generally indicated at 10, embodying the principles of the present invention which is of the type adapted to be attached to an exterior side of a vehicle. The assembly 10 includes, in general, a mounting shell 12 which is adapted to be connected with the side of the vehicle and to extend laterally outwardly therefrom. The shell 12 is exteriorly convex and interiorly concave and opens rearwardly when mounted in operative position on the vehicle. A power pack assembly, generally indicated at 14, constructed in accordance with the principles of the present invention is fixedly secured within the shell 12 and serves to mount a mirror case and mirror assembly 16 within the open rear of the shell 12 for pivotal movement about first and second intersecting axes normal to one another. The power pack assembly 14 includes first and second power operated moving mechanisms, generally indicated at 18, for moving the mirror case and mirror assembly 16 about the first and second pivotal axes respectively so as to move the same into any desired position of adjustment. As shown, the power pack assembly 14 includes a main molded plastic member 20 which is of generally thin wall configuration. In accordance with the principles of the present invention, the plastic member 20 is fixedly secured at spaced portions along the periphery thereof with spaced portions of the concave interior of the shell 12. In this way, the plastic member serves as a strengthening strut for the open rear of the shell. While any means for effecting the fixed securement may be utilized, preferably, there is formed on one end of the plastic member 20 a rearwardly extending wall portion 22 having a pair of parallel transversely extending slots 24 formed therein. The shell 12, which also is preferably molded of a plastic material, has formed in the interior thereof adjacent the end thereof which is nearest the side of the vehicle, a pair of parallel walls 26 having tongues 28 extending from the free ends thereof, as shown in Figure 2. The tongues 28 are adapted to extend completely through the slots 24 so that a free end portion thereof is beyond the slots. The thermoplastic material of each tongue 28 is then heated and fused or melted to spread out and engage over the material of the member 20 defining the associated slot 24, thus providing a fixed connection between the plastic member 20 and the shell 12 at that position. As best shown in Figures 1 and 3, additional similar fixed connections are spaced about the periphery of the plastic member 20 and with the shell 12, Figure 3 illustrates a rearwardly extending slot 30 in an opposite end portion of the member 20 through which a tongue 32 extends. The tongue 32 is formed on one cross of an X-shaped wall 34 integrally formed on the interior of the shell 12. As before, the plastic material of the tongue 32 is melted over to effect a rigid securement. Similar rearwardly extending slots 30 are provided in spaced portions around the periphery of the member 20. As with the connection shown in Figure 3, the shell 12 is provided with tongues 32 extending through the slots 30, each tongue 32 extending rearwardly from one cross member of an X-shaped wall 34 formed integrally on the interior of the shell 12. While any known power operated moving mechanism may be utilized in the power pack assembly 14, preferably, each of the power operated moving mechanisms 18 is constructed in accordance with the teachings of U.S. Patent 4,482,211. As best shown in Figure 5, each power operated moving mechanism 18 includes a reversible electric motor 36 including a housing having a pair of cylindrical bosses 38 extending outwardly from opposed ends thereof. An output shaft 40 extends axially through the bosses and one outwardly extending end of the shaft 40 has a worm gear 42 fixed thereto. The worm gear 42 is adapted to mesh with teeth 44 formed on the exterior of hollow rotary member 46. As best shown in Figure 4, the rotary member 46 has mounted therein for rotational movement therewith and for limited pivotal movement in one plane with respect thereto an internally threaded nut member 48. A motion transmitting member 50 is mounted with the nut member 48 and is provided with resilient fingers 52 having exterior threads engaging the interior threads of the nut member 48 so as to be moved rearwardly in response to one direction of movement of the motor 36 and forwardly in response to the opposite direction of movement of the motor 36. In accordance with the principles of the present invention, the main plastic member 20 has formed on the central portion thereof a rearwardly extending dual axis pivot element 54 in the form of a ball. As best shown in Figure 4, the mirror case and mirror assembly 16 include a mirror case 56 molded of a suitable plastic material to include a spherical socket 58 of a size to engage on the ball element 54. The ball and socket connection thus provided between the plastic member 20 and the mirror case 56 provide for universal movement including pivotal movement about first and second axes as aforesaid. Also in accordance with the principles of the present invention, the forward half of each power operated moving mechanism 18 is mounted within the plastic member 20 and the rearward half is mounted within a separate casing member 60. The two casing members 60 are also preferably molded of a suitable plastic material so as to have essentially identical configurations. As best shown in Figure 4, spaced along the first axis from the second axis there is formed in the plastic member 20 a cylindrical bearing or journal surface 62 having a rearwardly extending axis which intersects with the first axis, which, as shown, is a vertical axis. The cylindrical bearing surface 62 serves to journal a forward half of the rotary member 46 of the associated power operated moving mechanism 18. Extending radially inwardly from the cylindrical surface 62 is a rearwardly facing annual surface 64 against which a sinusoidal spring washer 66 is abutted. The spring washer 64 also engages the forward end of the rotary member 46 and serves to resiliently urge the same rearwardly. The associated casing member 60 is formed with a frustoconical bearing surface 68 within which the forward frustoconical end of the rotary member 46 is journalled when the associated casing member 60 is secured in operative position to the rear of the main plastic member 20, as by bolts 70, as shown in Figure 4. It will be understood that a second bearing surface 62 and annual surface 64 is provided in the plastic member 20 at a position spaced from the first axis along the second axis which, as shown, is a horizontal axis. As best shown in Figure 5, associated with each of the cylindrical surfaces 62 in the main plastic member 20 is a pair of axially spaced rearwardly facing semicylindrical surfaces 72 which are adapted to receive the forward halves of the cylindrical bosses 38 of the associated electrical motor 36. When retained in this position, the worm gear 42 on the end of the output shaft 40 of the motor 36 meshes with the gear teeth 44 on the outer periphery of the rotary member 46 so that the latter rotates in response to the rotation of the electrical motor 36. Each casing member 60 includes abutting surfaces 74 for engaging the bosses 38 to retain the same in accurately located position within the semicylindrical surface 72. It will be understood that each motor housing is flattened to engage within flattened cavities 76 and 78 formed in the members 20 and 60, respectively, to ensure that the motor housing does not turn. As shown in Figure 4, the rearwardly extending end of each motion transmitting member 50 is formed with a ball element 80 having shaft elements 82 extending radially outwardly therefrom in diametrically opposed relation. The mirror case 56 is formed with a slotted socket 84 for receiving each ball element 80 and associated shaft element 82. In this way, each motion transmitting member 50 is prevented from rotation by the engagement of the shaft elements 82 within the slots of the sockets 84. Moreover, each member 50 is also capable of pivotal movement at each end by virtue of the ball element 80 and the mounting of the associated nut member 48. It is believed that the manner in which the present mirror assembly 10 operates will be evident from the above. It will be understood that in accordance with conventional practice, the shell 12 is provided with attaching means (not shown) for attaching the same to the side of a vehicle. The attaching means may be either of the fixed type or of the resilient breakaway type. Moreover, as is usual with rearview mirror assemblies of the power operated type, a control lever mechanism is provided on the dashboard of the vehicle for operating the power operated moving mechanisms 18 by transmitting appropriate electrical currents thereto.

Claims: A rearview mirror assembly arranged to be attached to an exterior side of a vehicle, said assembly (10) comprising an exteriorly convex shell (12) having a concave interior opening rearwardly when said shell is mounted on the side of a vehicle, a mirror case (16), mounting means (20) secured to said shell and comprising dual axis pivot means (54), and means (58) carried by said mirror case in cooperating relation with said dual axis pivot means for mounting said mirror case within the open rear of said shell for pivotal movement about first and second intersecting pivotal axes normal to one another, a first power operated moving mechanism (18) carried by said mounting means including a first reversible electric motor (36) and a first rearwardly extending motion transmitting member (50) movable rearwardly in response to the rotation of said first motor in one direction and forwardly in response to the rotation of said first motor in an opposite direction, means (80) connecting the rearwardly extending end of said first motion transmitting member (50) with said mirror case along said first axis in spaced relation to said second axis so that the forward and rearward movements of said first motion transmitting member moves said mirror case in opposite directions about said second axis, a second power operated moving mechanism (18) carried by said mounting means including a second reversible electric motor (36) and a second rearwardly extending motion transmitting member (50) movable rearwardly in response to the rotation of said second motor in said one direction and forwardly in response to the rotation of said second motor in an opposite direction, means (80) connecting the rearwardly extending end of said second motion transmitting member (50) with said mirror case along said second axis in spaced relation to said first axis so that the forward and rearward movements of said second motion transmitting member moves said mirror case in opposite directions about said first axis, said assembly being characterised in that said mounting means comprises a moulded plastic member (20) of a size to fit within the concave interior of said shell (12) so as to extend inwardly of, and generally across, the open rear thereof, in that means (22, 26; 30, 32) are provided for fixedly securing spaced portions of said moulded plastic member (20) with spaced portions of concave interior of said shell so that said moulded plastics member serves as a strengthening strut for the open rear of said shell, in that said dual axis pivot means (54) comprises a dual axis pivot element (54) moulded integrally on the central portion of said moulded plastic member (20) and extending rearwardly therefrom, in that said moulded plastic member (20) has integral first and second one half mounting surface means (62) for engaging and supporting one fore and aft half of said first and second power operated moving mechanisms (18) respectively, and in that a pair of separate substantially identically configured first and second casing members (60) are fixed to said moulded plastic member (20) and have first and second other half mounting surface means (68) respectively for engaging and supporting the other fore and aft half of said first and second power operated moving mechanisms (18) respectively. A rearview mirror assembly as claimed in Claim 1, wherein said first and second motion transmitting members (50) have first and second longitudinal axes respectively, said first and second power operated moving mechanisms (18) comprising first and second hollow rotary members (46) respectively, said first and second one half mounting surface means comprising first and second annular surfaces (62) respectively for rotatably supporting one fore and aft half of said first and second rotary members respectively for rotation about first and second rotational axes respectively coinciding with said first and second longitudinal axes when said first and second motion transmitting members (50) are in their midpositions respectively, and said first and second other half mounting surface means including first and second annular surfaces (68) respectively for rotatably supporting the other fore and aft half of said first and second rotary members respectively. A rearview mirror assembly as claimed in Claim 2, wherein said first and second casing members (60) are centrally apertured within the first and second annular surfaces thereof so as to enable the first and second motion transmitting members (50) respectively to extend rearwardly therethrough. A rearview mirror assembly as claimed in Claim 2 or 3, wherein one pair of said first and second annular surfaces (68) is frustoconical and spring means (64) is provided for resiliently urging said first and second rotary members (46) into engagement with said first and second frustoconical surfaces respectively, the other pair of said first and second annular surfaces (62) being cylindrical to accommodate the resilient urging of said first and second rotary members respectively. A rearview mirror assembly as claimed in Claim 4, wherein said frustoconical surfaces (68) are on said casing members (60). A rearview mirror assembly as claimed in any preceding claim, wherein said first and second one half mounting surface means (62) comprises first and second pairs of axially spaced and axially aligned semi-cylindrical concave surfaces (72) for engaging said first and second electrical motors (36), each of said electrical motors (36) having a shaft rotatable about an axis concentric with the axis of associated cylindrical end bosses (38). A rearview mirror assembly as claimed in any preceding claim, wherein said fixedly securing means (22, 26; 30, 32) comprises spaced tongue (28, 32) and groove (24,30) connections in which the tongue of each section is formed of thermoplastic material and extends through the associated groove with a free end portion extending therebeyond, the free end portion of each tongue being fused to extend over the associated groove to accomplish the fixed securement.

Inventors: FISHER, ROBERT JAMES
Applicants: LOWELL ENGINEERING CORPORATION
Application year: 1988
Main classification: B60R1
IPC codes: B60R1, G02B7