Abstract:
A mirror assembly is provided for use on an external surface of a vehicle having a mirrored surface disposed in an external shell and a mirror flag operably connected to the external shell for attachment to an external surface of a vehicle. The mirror flag includes at least one spoiler disposed between the external shell and the mirror flag for directing air flow caused by forward movement of the vehicle. Specifically, the at least one spoiler serves to direct the air flow away from the mirror assembly as well as away from the vehicle surface to improve the aerodynamics of the vehicle and reduce wind noise produced by the air flow contacting the mirror.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a mirror assembly and, more particularly, to an improved mirror assembly for an automotive vehicle. 
     BACKGROUND OF THE INVENTION 
     In vehicle design, meeting aerodynamics and wind noise requirements is increasingly important, as well it is further desirable that a vehicle be capable of meeting occupant comfort requirements. In meeting both requirements, the design and placement of external components on an outer surface of a vehicle play a significant role. 
     Generally speaking, external components disposed on an outer surface of a vehicle, e.g., a side view mirror assembly, tend to adversely affect aerodynamics and increase passenger compartment noise. Accordingly efforts are made to design external components in conformance with the generally streamlined external surface of a vehicle. 
     The side view mirror assembly presents an aerodynamic design challenge because the mirror assembly not only has to be mounted on an outer surface of the vehicle, but must extend away from the surface to give the occupant a desired view behind the vehicle. In addition, side view mirrors assemblies are typically disposed at an angle to the vehicle body, as well as provide an adjustment mechanism to accommodate the varying viewing angle of different occupants. 
     The angular relationship of the mirror assembly to the body in combination with the distance the mirror assembly is typically disposed from the vehicle surface tends to create wind noise. Specifically, forward movement of the vehicle creates air flow over the external surface of the vehicle and over the side view mirror assembly. Generally speaking, this air flow creates wind noise due to the fact that the side view mirror assembly interrupts the flow of air over the vehicle surface and causes a turbulent flow of air behind the mirror assembly. Conventional mirror assemblies mitigate the effect of the air flow around the side view mirror assembly by including an external shell to redirect the air flow behind the mirror generally toward the vehicle body but away from the occupant to reduce the noisy condition. 
     The external shell of a conventional mirror assembly generally includes a hemispherical shape surrounding the mirror itself and serves to cut through the air flow and reduce wind noise. The hemispherical shape typically extends over the length of the leading edge of the mirror up to the opening of a mirror recess. Because the mirror is disposed at an angular relationship to the occupant the air flow is redirected at an angle generally towards the surface of the vehicle and often reacts against a surface of the vehicle generally rearward of the side view mirror. In this manner, the noise caused by the air flowing over the external shell of the side view mirror bypasses the mirror recess and often reduces the wind noise experienced by the occupant. 
     Current side view mirror assemblies further include a mirror flag for attachment to a vehicle, whereby the mirror flag joins the side view mirror assembly generally at the base of the mirror and connects to the vehicle body. Conventional mirror flags are often attached to the vehicle at the junction of the door glass frame and the door body and include a sweeping surface disposed between the side view mirror assembly and the vehicle and a triangular shaped portion attached to the vehicle. Mirror flags further cooperate with the generally hemispherical surface of the side view mirror assembly to facilitate movement of the air flow over the side view mirror and away from the mirror recess to a location on the vehicle body generally behind the occupant. In this manner, mirror flags typically assist in redirecting the air flow caused by the moving vehicle generally towards the door and away from the mirror recess. 
     Conventional side view mirror assemblies and mirror flags, while preventing air flow from entering the mirror recess and reducing wind noise, do not completely satisfy the problem of wind noise caused by the flow of air over the side view mirror assembly. Specifically, conventional side view mirror assemblies and mirror flags generally suffer from the fact that the air flow is forced to flow towards the vehicle where it often contacts other external components such as door handles and weather stripping. Air flow contact with these external components creates additional wind noise. This condition is usually worsened, for example, when the front door glass is down and the door B-pillar is exposed. In this situation, the B-pillar acts as a pocket to catch the air flow from the side view mirror, thus creating pulsation of the passenger compartment air cavity. The noise caused by the pulsation is referred to as buffeting. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention provides a mirror assembly for use on an external surface of a vehicle having a mirrored surface disposed in an external shell and a mirror flag operably connected to the external shell for attachment to an external surface of a vehicle. The mirror flag includes at least one spoiler disposed between the external shell and the mirror flag for directing air flow caused by forward movement of the vehicle. In accordance with one aspect of the present invention, a plurality of spoilers can be employed. Specifically, the at least one spoiler serves to direct the air flow both away from the mirror assembly as well as the vehicle surface, resulting in improved window-down buffeting and reduced turbulence. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
     FIG. 1 is a partial perspective view of an automotive vehicle including a mirror assembly in accordance with the principals of the present invention; 
     FIG. 2 is a rear elevational view of the mirror assembly of FIG. 1; 
     FIG. 3 is a perspective view of a spoiler in accordance with the principals of the present invention; 
     FIG. 4 is a top elevational view of the mirror assembly of FIG. 1; and 
     FIG. 5 is a perspective view of a mirror assembly in accordance with the principals of the present invention depicting a spoiler disposed on a bottom surface of the mirror assembly. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     With reference to the figures, a mirror assembly  10  is provided and includes a mirror  12 , an external shell  14 , and a mirror flag  16 . The mirror  12  is generally disposed within the external shell  14  while the mirror flag  16  serves to support the external shell  14  and the mirror  12 . In one embodiment, the mirror  12  is positionable relative to the external shell  14 , while in another embodiment, the external shell  14  is positionable relative to the mirror flag  16 , as will be discussed further herein below. 
     The external shell  14  serves as a housing for the mirror  12  and includes a generally hemispherical outer surface  18 , a recess  20 , and a bottom surface  21 . The hemispherical surface  18  extends generally over the entire outer surface of the shell  14  and terminates at the edge of the recess  20  as best shown in FIG. 4. A plane  22  is created at the junction of the recess  20  and the hemispherical outer surface  18  along axis Y as shown in FIG.  4 . The plane  22  establishes the angular relationship of the recess  20  to an external surface, whereby the angular relationship is shown as ψ by way of reference in FIG.  4 . In one embodiment, the external surface is a body panel of a motor vehicle  24 , whereby the external shell  14  serves to fixedly hold the mirror  12  in a fixed relationship to the body  24 . In this manner, the plane  22  defines the angular relationship of the external shell  14  to the external surface of the vehicle  24 . Alternatively, the external surface is a door assembly  52 , whereby the external shell  14  serves to fixedly hold the mirror  12  in a fixed relationship to the door assembly  52 . In this manner, the plane  22  defines the angular relationship of the external shell  14  to an outer surface of the door assembly  52 . 
     The mirror  12  is disposed in the recess  20  of the external shell  14  and includes a reflective surface  28 . The reflective surface  28  can be shaped such that it completely fills the recess  20  of the shell  14  as best shown in FIG.  2  and is disposed generally along the plane  22 . As such, the relationship of the mirror  12  to the external surface of the vehicle  24  is generally governed by the relationship of the plane  22  to the external surface. In one embodiment the mirror  12  is permitted to rotate relative to the external shell  14  and, therefore, may be positioned at a different angular relationship relative to an external surface than the angular relationship of the plane  22  to the same external surface. In this manner, a slight clearance  30  is provided between an interior surface  32  of the shell  14  and an edge  34  of the mirror  12  to accommodate movement of the mirror  12  within the recess  20 , as best shown in FIG.  2 . 
     The external shell  14  further includes a first spoiler  36  disposed adjacent the bottom surface  21  of the shell  14 , as best shown in FIG.  5 . The first spoiler  36  is an arcuate fin generally extending along the bottom surface  21  of the shell  14  and serves to redirect the air flow around the mirror assembly  10  and away from the vehicle. With particular reference to FIG. 3, the first spoiler  36  includes a generally straight section  45  extending from the mirror flag  16  and includes a junction  47  formed in cooperation with a surface of the mirror flag  16 . In this manner, the junction  47  causes the air flow to be forced against the mirror flag  16  and subsequently along the first spoiler  36 . 
     With continued reference to FIG. 3, the straight section  45  extends from a surface of the mirror flag  16  and terminates at a curved portion  49  of the first spoiler  36 . The curved portion  49  includes a convex surface  38  extending away from plane  22  and a concave surface  40  extending generally towards plane  22 . In this manner, the first spoiler  36  extends outwardly towards plane  22  and terminates at a tip  42 . In addition, the first spoiler  36  includes a reaction surface  44  disposed along the length of the first spoiler  36 , generally extending from the straight portion  45  along the concave surface  40  and terminating at the tip  42 . 
     As previously mentioned, the air flow contacting the junction  47  reacts against the mirror flag  16  and is caused to flow generally along the first spoiler  36 . Specifically, as the air flow moves from the junction  47 , it first contacts the straight portion  45  and generally contacts the reaction surface  44  and the bottom surface  21  of the external shell  14 . Once the air flow reaches the curved portion  49  of the first air foil  36  it continues to react against the bottom surface  21  and the reaction surface  44  but now contacts the concave surface  40  as well and begins to move towards the tip  42 . Once the air flow has traveled sufficiently along the concave surface  40  and reaches the tip  42  it effectively flows over the tip  42  and away from the vehicle  24 . As such, the curvature of the concave surface  40  and location of the tip  42  generally define when and in what direction the air flow will depart the first spoiler  36 . 
     In one embodiment, the mirror assembly  10  may be mounted to an external surface of a vehicle body  24  as previously discussed. As such, the mirror assembly  10  is subjected to an air flow caused by forward movement of the vehicle (not shown). The external shell  14 , and subsequently plane  22 , are positioned at an angle relative to the external surface of the vehicle  24  to provide the occupants with a view of an area behind the vehicle  24 . In this manner, the air flow will first contact the hemispherical outer surface  18  of the shell  14  and be caused to flow over the mirror assembly  10 . 
     To mitigate the tendency of the air flow to be trapped by the recess  20 , and thus create wind noise, the first spoiler  36  traps the air flow between the bottom surface  21  and the reaction surface  44 . Because the first spoiler  36  is disposed such that the concave portion  40  faces plane  22  and opens at tip the  42 , the air flow is trapped between the bottom surface  21  of the shell  14  and the reaction surface  44  of the first spoiler  36 . Thus, the air flow is forced along a path following the concave surface  40  towards the tip  42  until it finally is moved away from the mirror assembly  10 . The first spoiler  36  redirects the air flow caused by the forward movement of the vehicle down and away from not only the mirror assembly  10  but also from the vehicle  24 , thereby reducing the wind noise associated with the air flow contacting mirror assembly  10  and the vehicle  24 . 
     The mirror flag  16  serves to support the external shell  14  and, thus, the mirror  12 , and includes a mounting bracket having a generally triangular shape and an arm  48  interconnecting the mirror flag  16  and the shell  14 . In one embodiment the arm  48  and the external shell  14  are integrally formed such that the shell  14  is not permitted to move relative to the arm, while in another embodiment the arm  48  rotatably supports the shell  14  such that the shell  14  is permitted to rotate relative to the mirror flag  16 . 
     The mounting bracket of the mirror flag  16  includes a flat portion  50  for engagement with an external surface. In one embodiment, the mounting bracket fixedly mounts to the vehicle  24 , while in another embodiment the mounting bracket fixedly mounts to a door assembly  52  of the vehicle  24 . It should be noted that while a mounting bracket having a generally triangular shape and including a flat portion  50  is disclosed, any shape accommodating an outer surface of a vehicle is anticipated and should be considered within the scope of the present invention. 
     The arm  48  outwardly extends from the attachment bracket and includes a rounded leading edge  54  and a second spoiler  56  integrally formed thereon. The leading edge  54  serves to cut through an air flow and redirect the air flow towards both the bottom of the shell  14  and the top of the arm  48  such that the air flow contacts the first and second spoilers  36 ,  56 . 
     The second spoiler  56  extends generally between the mounting bracket and the arm  48  and serves to redirect an air flow away from the shell  14  and the recess  20 , thereby reducing wind noise. In one embodiment the mirror assembly  10  is fixedly mounted to the external surface of the vehicle  24  and as such the second spoiler  56  serves to redirect the air flow away from the vehicle  24 . The second spoiler  56  has a generally flat leading edge  58  disposed at an angular relationship to the mounting bracket and includes a reaction surface  60  disposed along its length as best shown in FIGS. 1 and 4. It should be noted that FIGS. 1 and 4 include a shaded surface to better show the leading edge  58  and reaction surface  60  and as such should not be construed as additional structure. 
     In operation, the second spoiler  56  receives an air flow, whereby the air contacts the reaction surface  60  of the leading edge  58  and is caused to move generally away from the recess  20  and over the leading edge  58 . Specifically, the reaction surface  60  causes the air flow to move at an angle to the vehicle body  24  up until the air flow reaches the leading edge  58 . At this point, the air flow departs the second spoiler  56  and is caused to move away from both the mirror assembly  10  and the vehicle  24  and thus reduces wind noise experienced by the occupant. 
     While first and second spoilers  36 , 56  have been disclosed as integrally formed with the shell  14  and the mirror flag  16 , it should be understood that the spoilers  36 , 56  could be formed separately and fixedly attached to the mirror assembly  10  such as in an aftermarket condition or as a separate vehicle accessory. 
     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.