Rear view mirror with integral light assembly

Abstract: A mirror assembly security system for a vehicle includes an exterior mirror assembly 26' and a light module 104 removably positioned within the exterior mirror housing. The light module is moisture impervious and includes an enclosure 116, a light-transmitting opening 122 in the enclosure facing generally downwardly and/or rearwardly of the vehicle, a cover 130 for the light-transmitting opening, and a light source 126 in the enclosure radiating light through the light-transmitting opening. The light source may be received in a socket which removably engages another opening in the enclosure.

Description: This invention relates generally to a signal light module for a vehicle mirror assembly and to the mirror assembly itself. The invention is particularly adapted for incorporation in the exterior mirrors of a vehicle. GB 2,275,329 A discloses a signal light module according to the preamble of claim 1, positioned in a vehicle exterior mirror assembly. Within the assembly, a light source is housed in an enclosure having a light-transmitting opening, the opening being covered with a lens. The light source radiates light generally along a light-radiating axis that extends rearwardly away from the passenger compartment of a vehicle in order to shield the driver from light radiated by the light source. The present invention provides a signal light as described above incorporated in a signal light module which is adapted to be removably positioned in an opening in a vehicle exterior mirror assembly characterised in that the light source comprises a plurality of light-emitting diodes with louvers therebetween in the enclosure, in order to shield the driver from light radiated by the diodes. Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which: Fig. 1 is an exploded perspective view taken from the front of a mirror assembly (rear of the vehicle), according to an embodiment of the present invention; Fig. 2 is an exploded perspective view illustrating details of the light module of Fig. 1; Fig. 3 is a sectional view taken along the lines XXIII-XXIII in Fig. 2; and Fig. 4 is a front elevation of the mirror assembly in Figs. 1 and 2 illustrating the manner in which a light module is removably mounted to an exterior rearview mirror housing. A vehicle personal security lighting system 25' includes a light module 104 that is removably positioned within housing 34' of exterior mirror assembly 26' (Fig. 1). In addition to the opening for accepting bezel or cowling 106, mirror housing 34' includes a downward opening 108 for receiving light module 104. Additionally, bezel 106 includes a recess 110 which defines an opening facing generally downwardly and rearwardly of the vehicle. Exterior mirror assembly 26' includes a bracket 43' for mounting positioning device 42 which mounts reflective element 28. Bracket 43' has two pairs of flexible prongs 112, which are received within sockets 114 defined on an enclosure 116 of light module 104. Prongs 112 releasably engage sockets 114 in order to retain the light module within the exterior mirror assembly in openings 108 and 110. Light module 104 may be disassembled from exterior mirror assembly 26' by reaching behind reflective element 28 with a pair of needle-nose pliers, or the like, and sequentially compressing each of the pairs of prongs 112 in order to release the prongs from sockets 114. Thus, prongs 112 and sockets 114 provide a fastener-less system which retains the light module in the exterior mirror assembly without the use of separate fasteners. A pair of shoulders 118, which define a slot 120 therebetween, engage a protrusion from an inner surface (not shown) of housing 34' in order to assist in stably positioning light module 104 within housing 34'. Alternatively, one or more fasteners, such as screws, clasps, latches, clips, and their like could be used. But, preferably, for ease of serviceability and for consumer acceptability, only one, and at most two, such fastener should be used. A further advantage of a fastener-less system is that it facilitates supply of a light module for use in a plurality of exterior mirror assemblies manufactured by a multitude of exterior mirror manufacturers with minimum modifications to the complete mirror assembly housing. Unitary enclosure 116 has a generally downwardly directed light-transmitting opening 122 and an opening 121 for receiving a light socket 124. Light socket 124 provides electrical connection to a light source 126, which is electrically interconnected to the vehicle through a cable 128. The socket may be self-gasketing, achieved by selection of a material in its construction, at least at the mating surface, that achieves a sealing function. Preferably, the socket, either wholly, or partially at least at its mating surface, is a resilient, somewhat flexible polymer material, preferably with a durometer hardness, measured on the SHORE A scale of less than approximately 95, more preferably less than approximately 85, and most preferably less than approximately 75 but preferably of SHORE A hardness greater than about 50, and preferably greater than about 60. Materials appropriate to achieve this, and simultaneously have the physical, mechanical, and high temperature performance needed, include silicone, urethanes, thermoplastic rubbers, and polyvinyl chloride. Preferably, the material used for the self-gasketing socket is capable of withstanding temperatures in use in excess of approximately 200°F (93.3°C) or higher. Alternatively, a rigid construction may be used for the light socket, such as a ceramic, engineering plastic, Bakelite, nylon, polyester, filled polyester, or filled (glass and/or mineral) nylon, if a gasketing material delivering the above properties are used at the point of mating of light socket 124 and enclosure 116. Light socket 124 seals against enclosure 116 by the provision of a gasket, which, in the illustrated embodiment, is provided by the flexible nature of light socket 124. Alternatively, a separate gasket member formed of material such as silicone, neoprene, thermoplastic rubber, EPDM, polypropylene/EPDM alloy and similar elastomeric materials, preferably having the hardness properties listed above, could be inserted between the light socket and the enclosure. Light-transmitting opening 122 is covered by a cover member 130. Cover member 130 is a lens member, which affects the distribution of light emitted from light source 126. In the illustrated embodiment, cover member 130 is a clear optic lens that provides a substantially uniform puddle of light on the illuminated area adjacent the vehicle's door having a relatively wide light pattern, or flood pattern. Alternatively, cover member 130 could be a diffractive optic, a diffusive optic, a refractive optic, a reflective optic, a holographic optic, a binary optic, or a sinusoidal optic. In the illustrated embodiment, light source 126 is an incandescent lamp that is a filament optic having a minimum five-candle power. Such candle power mounted within an exterior mirror assembly of an automobile will preferably produce a ground surface illumination intensity of at least approximately 5 lux or greater, more preferably at least about 10 lux, and most preferably at least about 20 lux. Light source 126 may range in power up to 32-candle power or more. The preferred range is between approximately 5-candle power and approximately 15-candle power. It is desirable to provide as much candle power as possible without creating excessive heat within enclosure 116. If a high wattage lamp is used, a ventilation system is provided. Ventilation techniques are known in the art which allow the passage of air through the cavity 134 in which the light source is positioned while providing a substantially moisture-impervious barrier. Light module 104 additionally includes a reflector 132 surrounding light source 126, both positioned in a cavity 134, which extends to light-transmitting opening 122. The purpose of the reflector is in order to direct the light from light source 126 into the pattern of light illustrated in Figs. 10-12 of GB 2,275,329. Reflector 132 may be a parabolic reflector, as illustrated in Fig. 3, but may additionally include an extended tunnel in order to provide collimation of the light beam. In the illustrated embodiment, reflector 132 is aluminum or high efficiency aluminum vacuum-deposited on a wall 133 defining cavity 134, with an optional coating of lacquer. Alternatively, wall 133 may be coated with a white paint, such as "Argent" white or a silver paint. Reflector 132 may be a separate member, such as stamped metal or an aluminized glass optic. Alternatively, light source 126 and reflector 132 may be provided as an assembly. Light module 104 includes a second cavity 140 defined in enclosure 116 and extending to a second light-transmitting opening 136. A signal light assembly 138 is positioned within cavity 140 to radiate light rearwardly with respect to the vehicle. Signal light assembly 138 includes a pair of electrical contacts 142, which protrude through grooves 144 defined in a flange 146 surrounding opening 136. Contacts 142 engage a connector 148, which provides electrical connection between signal light assembly 138 and the vehicle through cable 128 which, in turn, may piggyback or otherwise connect to existing 12-volt battery/ignition wiring already supplied in the housing to service an electrical actuator and/or a defroster heater pad. Signal light assembly 138 includes a plurality of light-emitting diodes 152 positioned on circuit board 150. A variety of emitting sources may be used as light-emitting source 90, including, but not limited to, very high intensity amber and reddish-orange light-emitting diode (LED) sources, such as solid-state light-emitting diode (LED) sources utilizing double heterojunction AlGaAs/GaAs material technology, such as very high intensity red LED lamps T-1 3/4 (5 mm) HLMP-4100/4101, available from Hewlett Packard Corporation, Palo Alto, California, or which use transparent substrate aluminum indium gallium phosphide (AlInGaP) material technology, commercially available from Hewlett Packard Corporation, Palo Alto, California under the designation T-1 3/4 (5mm) HLMT-DL00, HLMT-CH00, HLMT-CL00, HLMT-CH15, HLMT-CL15 and HLMT-DH00 or high power AlInGaP amber and reddish-orange lamps under the designation HLMA-CHOO/-CLOO, HLMA-DGOO/-DHOO/-DLOO, HLMA-EH2O/-EL2O, HLMA-KH00/-KL00, and HLMA-QHOO/-QLOO, or which use InGaAlP material technology available from Toshiba Corporation of Latham, New York, such as under the designation TLRH180D or GaAlAs/GaAlAs LED sources available from Sharp Corporation Electronics Components Group such as Model No. GL6UR31T and Model No. GL6UR3T which are red LEDs. Light emittance colors provided by such solid-state sources include orange, yellow, amber, red, and reddish-orange, desirably without need of ancillary spectral filters. The preferred solid-state light-emitting diodes, at 25°C or thereabouts, operate at a forward voltage of about 2 volts to about 5 volts; have a luminous intensity (measured at the peak of the spacial radiation pattern which may not be aligned with the mechanical axis of the source package) of a minimum, at 20 mA current, of about 500 to about 5000 mcd (typical, about 700 to about 7000 mcd); operate at a forward current of about 20 mA to about 50 mA; emit with a dominant wavelength (CIE Chromaticity Diagram) of about 530 nm to about 680 nm; and have a viewing angle 2Θ½ (where Θ½ is the off-axis angle where the luminous intensity is one half the peak intensity) of about 5° to about 25°. A lens assembly 154, which may be a polycarbonate or acrylic material, is positioned over signal light assembly 138. Lens assembly 154 may include a clear or sinusoidal optical surface 156 and a plurality of louvers 158. Louvers 158 and light-emitting diodes 152 are skewed away from the passenger compartment of the vehicle. In the illustrated embodiment, the light-emitting diodes and louvers are skewed at an angle of at least approximately 15°, more preferably approximately 20°, and most preferably approximately 25° to 30° from the longitudinal centerline of the vehicle, but preferably not more than about 45°. The purpose of the skewing is in order to allow the light radiated by the signal light assembly to be visible by drivers in vehicles to the side of vehicle 40, but to be shielded from the driver of the vehicle 40. This features prevents distraction to the driver of the vehicle equipped with the security lighting system. A cover member 160 encloses signal light assembly 138 and sinusoidal optical surface 156 by moisture-tight engagement with flange 146 of enclosure 116. In the illustrated embodiment, light-emitting diodes 152 are individually mounted at an angle on circuit board 150. In an alternative embodiment, light-emitting diodes 152 could be mounted upright, normal to circuit board 150, with the entire signal light assembly mounted at an angle with respect to the vehicle passenger compartment in order to provide proper skewing away from the driver of the vehicle equipped with the mirror assembly security system. Also, when desired, a current limiting resistor can be mounted on circuit board 150 in series with the light-emitting diodes 152 to limit current therethrough and to mate to the 12-volt ignition/battery potential servicing the exterior mirror assembly. Enclosure 116 is made from a heat-resistant material and is substantially moisture impervious. Preferably, a polymer material is used which has a heat distortion temperature (as measured by ASTM D 648 for a 12.7 x 12.7 x 6.4 mm specimen and at 1820 kPa) of at least approximately 80°C, more preferably at least approximately 100°C, and most preferably at least approximately 120°C. A mineral-filled or glass-filled nylon or polyester or acrylonitrile butadiene styrene (ABS) polymer may be utilized for enclosure 116. In the illustrated embodiment, enclosure 116 is made from polycarbonate with cover members 130 and 160 made from a polycarbonate or acrylic. The components of enclosure 116 may be assembled by conventional sonic welding, vibration welding, or by the use of suitable adhesives. Enclosure 116 is opaque, except for cover members 130 and 160, in order to shade light. The light module fits within the cavity defined within housing 34' by openings 108 and 110 in a manner which conforms to the styling and aerodynamic lines of the housing. Light modules according to embodiments of this invention, including a ground illumination lamp and a signal light incorporated into an exterior mirror assembly, were mounted and driven on vehicles through a variety of driving conditions and through varied environmental exposure, and were found to have the performance and environmental resilience required by automakers so as to be suitable for commercial use on vehicles. Although illustrated herein as being located along the bottom rim of the exterior trim housing, other locations are possible for the signal light, including the top and outboard rim of the exterior rim housing, and even elsewhere on the exterior vehicle body as appropriate. Should it be desired to vary the intensity of the signal lights so they are brightest during high ambient lighting conditions, such as on a sunny day, but so that they are dimmer when ambient conditions are lower, such as at night, the intensity of signal light can be modulated using a photosensor such as a photoresistor, photodiode, phototransistor, or their like. A photosensor that controls the intensity of the signal light so that it reduces its intensity during low ambient light driving conditions, such as by pulse width modulation on the electrical line powering the LEDs in the signal light, may be mounted integrally with the lamp module itself, or it may be part of the vehicle electronics itself, such as a photosensor mounted as a part of an automatic electrochromic mirror circuit, as part of a vehicle automatic headlamp activation circuit, as part of a headlamp daylight running light control circuit, or their like. Also, the invention is applicable to a variety of exterior vehicular mirror assembly constructions, including one-part designs, uni-body constructions, and their like, as known in the exterior mirror assembly art. The invention is applicable to a variety of assemblies including assemblies that use a bracket as a distinct internal structure and assemblies that do not use a bracket but rather are bracket-less assemblies where the housing itself serves as a structural element with means such as on the walls of the housing for securing an actuator and for receiving a lamp module.

Claims: A signal light module (104) adapted to be removably positioned in an opening (108,110) in a vehicle exterior mirror assembly (25') comprising: an enclosure (116), a light source (152) and a light-transmitting opening (136) in the enclosure, the opening being covered with a lens (154), wherein the light source radiates light generally along a light-radiating axis that extends rearwardly away from the passenger compartment of a vehicle in order to shield the driver from light radiated by the light source, characterised in that the light source comprises a plurality of light-emitting diodes (152) with louvers (158) therebetween in the enclosure. An exterior mirror assembly (25') comprising the signal light module (104) as claimed in claim 1 said mirror assembly further including a reflective element (28) contained within a first housing and the light module (104) removably positioned in the first housing, the light module including a second enclosure (133), a light-transmitting opening (122) in the second enclosure facing generally downwardly and/or rearwardly of the vehicle, a cover (130) for the light-transmitting opening, and a second light source (126) in the second enclosure radiating light through the light-transmitting opening. The mirror assemblyas claimed in claim 2 including a socket (124) positioned in a further opening (121) in the second enclosure and including a means for sealing the socket in the further opening, whereby the light source can be replaced by removing the light module from the housing and removing the socket from the light module. The mirror assembly as claimed in claim 2 or 3, further including a light-directing surface (132) at least partially surrounding the light source in the second enclosure. The mirror assembly claimed in claim 2 to 4, wherein the second enclosure slopes from the cover (130) rearwardly and upwardly to a location behind the reflective element (28). The mirror assembly claimed in claim 2 to 5 wherein the light module is substantially moisture impervious. The mirror assembly claimed in claim 2 to 6 including means defining an airflow path through the second enclosure in order to dissipate heat from the light source. The mirror assembly claimed in claim 2 to 7 wherein the light module is mounted in the housing in a manner that defines a drain from the housing for water in the housing. The mirror assembly claimed in claim 2 to 8 wherein the second light source is an incandescent lamp. The mirror assembly claimed claim 2 to 9 including mating surface configurations (112,114) on the housing and the second enclosure which at least partially retain the enclosure in the housing. The mirror assembly as claimed in claim 2 wherein said louvers are skewed at an angle of at least approximately 15° from the longitudinal centerline of the vehicle.

Inventors: PASTRICK TODD W, PASTRICK, TODD W.
Applicants: DONNELLY CORP, DONNELLY CORPORATION
Application year: 1996
Main classification: B60R1
IPC codes: B60Q1, B60R1