Abstract:
A hinge construction for a wing mirror unit for a motor vehicle is proposed that comprises a first hinge part for mounting on the motor vehicle and a second hinge part, pivotably connected therewith via a shaft. The second hinge part supports a mirror frame of the wing mirror unit, wherein the shaft is connected with one hinge part and wherein the other hinge part is arranged pivotably about the shaft. The mirror frame has a location guide that corresponds with a location rib of a power fold module that is inserted into the frame.

Description:
BACKGROUND ART 
     The invention is based on a priority patent application EP 09171051 which is hereby incorporated by reference. 
     FIELD OF THE INVENTION 
     The invention is related to a hinge construction for a wing mirror unit for a motor vehicle that comprises a first hinge part for mounting on the motor vehicle and a second hinge part, pivotably connected therewith via a shaft. The second hinge part supports a mirror frame of the wing mirror unit, wherein the shaft is connected with one hinge part. 
     More especially the invention provides a solution to fit the powerfold into the mirror frame. 
     In addition a solution is proposed to decouple motor of powerful efficient from the motor worm that transfers the forces into a wing mirror motion. 
     DESCRIPTION OF THE RELATED ART 
     This invention relates to a hinge construction, in particular for a wing mirror unit of a motor vehicle, comprising a first hinge part for mounting on a motor vehicle and a second hinge part, pivotably connected therewith, for supporting a mirror frame of the wing mirror unit. Such a hinge construction is generally known and typically comprises a first hinge part which is designed as a base plate for mounting on a door of an automobile. The base plate then mostly supports a fixed shaft of substantially upright orientation. The second hinge part typically comprises a mirror frame, arranged so as to be pivotable about the shaft. The mirror frame supports the components of the wing mirror, such as a mirror adjustment mechanism with mirror glass and a mirror housing. 
     By means of the hinge construction, the wing mirror is operatively adjustable between a folded-in position, in which the wing mirror substantially abuts alongside the body of the motor vehicle, and a folded-out position, in which the wing mirror is oriented substantially transversely to the body of the motor vehicle. 
     Through this adjustability, the wing mirror can be folded in from the folded-out operating position to a folded-in position in which the mirror housing projects less far with respect to the body. In this way, for one thing, the risk of damage to the wing mirror when parking the vehicle can be reduced and the wing mirror can yield to some extent upon collision with an object. 
     Typically, the hinge construction comprises an electric drive mechanism with which the wing mirror is adjustable between the folded-in position and the folded-out position. In connection with safety and aerodynamics, the wing mirror in the folded-out position is preferably placed as closely to the body as possible. 
     The electrical fold-in function of the wing mirror should not result in vibrations during driving. In addition the noise level of the motor drive must be as low as possible for OEM&#39;s purpose. 
     Another need of a wing mirror with a power fold equipment is that the assembly of the whole mirror must be as reliable as possible to avoid quality problems. In the EP 1908633 A1 a hinge construction is described that combine the mounting of gear elements in a rigid box. The worm gear is fixed between a separation element connected to the motor and a fixed housing lower part with a separate pin. This construction does not allow an easy mounting of the worm gear. 
     SUMMARY 
     To resolve all requirements, complex constructions have been proposed. 
     This invention contemplates an alternative construction, with which the same advantages can be achieved. In particular, the invention contemplates a simple, reliable construction with which the advantages can be achieved in a simple, operatively reliable manner. The invention shows a solution easy to mount and able to damp vibrations and motor noise. 
     To that end, the invention provides a hinge construction for a wing mirror unit for a motor vehicle, comprising a first hinge part for mounting on the motor vehicle and a second hinge part, pivotably connected therewith via a shaft, for supporting a mirror frame of the wing mirror unit, wherein the shaft is connected with one hinge part and wherein the other hinge part is arranged pivotably about the shaft and the power fold module is formed by a gear box and an upper case with a seal cover, wherein the upper case comprises a socket with an axis separation part between motor and motor worm and the motor worm is borne between a bearing in the socket and a worm cap bearing in the worm cap, characterized in that the worm cap bearing is part of a worm cap snapped to a supporter of the upper case. 
     By coupling the drive mechanism disengageably with one of the hinge parts, what can be achieved is that the drive mechanism can be uncoupled when from outside a high adjusting force is exerted on the hinge construction. 
     The invention also relates to a wing mirror unit, in particular for a motor vehicle, comprising a hinge construction, wherein the first hinge part is provided with a base plate for mounting on the body of a motor vehicle and wherein the second hinge part is provided with a wing mirror, and wherein the wing mirror is adjustable during use between a folded-in position, in which the wing mirror substantially abuts along the body of the motor vehicle, and a folded-out position, in which the wing mirror is oriented substantially transversely to the body of the motor vehicle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention is shown in the figures and shortly described there after. 
         FIG. 1  shows a perspective view of a separated shaft ( 10 ) from said power fold module. 
         FIG. 2   a  shows a top view showing the outside mirror and section view showing the power fold unit when the outside mirror is drive position. (fold-out position) 
         FIG. 2   b  shows a top view showing the outside mirror and section view showing the power fold unit when the outside mirror is park position. (fold-in position) 
         FIG. 2   c  shows a top view showing the outside mirror and section view showing the power fold module when the outside mirror is rotated forward due to the external impact. (fold-over position) 
         FIG. 3  shows a perspective view showing the power fold unit of this invention for outside mirror. 
         FIG. 4  shows a cross sectional view showing the power fold module of this invention for outside mirror 
         FIG. 5   a  shows a front view showing the shaft 
         FIG. 5   b  shows a top view showing the flange of a shaft 
         FIG. 5   c  shows a cross sectional view showing a shaft 
         FIG. 6   a  shows a top view showing the flange of a shaft 
         FIG. 6   b  shows a bottom view showing the gear box 
         FIG. 7   a  Perspective view showing essential portion of a shaft 
         FIG. 7   b  Perspective view showing essential portion of the gear box 
         FIG. 8  shows a partial assembly drawing of an upper case 
         FIG. 9  shows a partial assembly drawing of a gearbox 
         FIG. 10  shows a cross sectional view showing a frame of outside mirror 
         FIG. 11  shows a bottom view showing the frame of outside mirror 
         FIG. 12  shows an assembly drawing of frame of outside mirror. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In  FIG. 1  a wing mirror with a base  100  and a mirror head  50  is shown. A shaft  10  is fixed on the base  100  and the rest of power fold module  30  is mounted on the mirror head  50 . 
     This mechanism is working in that the power fold module  30  including the mirror head  50  rotates around the shaft  10  to the specific position (fold-in position and operational position). 
     The shaft  10  which is an axis for rotation to specific position of the mirror head  50  is mounted on the base  100  of the wing mirror. Details of the shaft are shown in  FIG. 7   a . The circumference surface of the shaft  10  has shaft projections  13 - 1 ,  13 - 2 ,  14 - 1 ,  14 - 2  arranged along two radii of regular angle on the shaft flange  12  for controlling fold-in position  71  and neutral position  70  of the power fold module. 
     The center of the shaft  10  is open and allows a wiring through the hole. In a preferred embodiment the harness of the mirror head passes completely through the hole to connect mirror head with the vehicle&#39;s electrical system. The shaft  10  has a long tube-like body to be assembled to a gearbox  20 . This shaft projecting part  11 , has a regular external diameter φθ, a wall thickness t and a length L for strong support of power fold module and mirror head part. 
     The lower portion of shaft projecting part  11  forms the wiring hole  18  that is surrounded by a shaft flange  12 . Between outer side of the shaft flange  12  and the shaft projecting part  11  shaft inner projections  13 - 1 ,  13 - 2  and shaft outer projections  14 - 1 ,  14 - 2  are arranged. 
     Shaft inner projections  13 - 1 ,  13 - 2  are symmetrically formed around the opening of the wiring hole  18 . The shaft outer projections  14 - 1 ,  14 - 2  are formed at the outer side of the shaft flange  12  and symmetrically formed around basis of wiring hole  18 . 
     All shaft projections  13 - 1 ,  13 - 2 / 14 - 1 ,  14 - 2  are spaced apart 90° from each other. The shaft projections  13 - 1 ,  13 - 2 / 14 - 1 ,  14 - 2  have specific slopes α at the end faces of the projections. The radial lengths of the projections are defined by angles Q 1 , Q 1 ′, Q 2 , Q 2 ′ of radial shape as shown in  FIG. 6   a.    
     The end faces inclined by angle α form the shaft stopper parts  15 ,  16  of the shaft projections  13 - 1 ,  13 - 2 ,  4 - 1 ,  14 - 2 . The shaft stoppers parts  15 ,  16  support the end stop positions for the wing mirror, when power fold module is stopped in neutral position  70  or fold-in position  71 . 
     In neutral position  70  or fold-in position shaft inner stopper parts  15  and faces of shaft outer stopper parts  16  are in contact with gearbox inner stopper parts  24  and gearbox outer stopper parts  25  at the same time. The close connection of shaft and gear box allows a stable solution for the pivotable wing mirror. 
     When the mirror head part  50  of wing mirror is rotated from neutral position  70  to fold-over position  72  due to an external impact, four faces of shaft stopper parts  15 ,  16  contact four faces of gearbox stopper parts  24 ,  25  which allows a stable end position. 
     After the mirror head part  50  overcomes the shaft stopper parts  15 ,  16  by compulsion impact, it is possible to use the hand or a switch which is installed in vehicle for return to drive position  70 . 
     The gear box  20  of  FIG. 7   b  has cylindrical hole  28  which has specific dimension to allow assembling of shaft projection  11 . The hole  28  is surrounded by the gearbox circular working face  27  that forms the correspondence surface to the friction surface of shaft  10  for sliding and/or rotation on friction surfaces. The surface  27  in the gear box  20  includes a metal plate  40  that reduces the slide coefficient and the abrasive degrading of the surface. The gear box is manufactured by injection molding of high stiffness plastic, the thin metal plate  40  is inserted after molding process into the gearbox  20  for preventing damage when mirror is rotated fold over position by external impact. 
     The outer radius of gearbox circular working face  27  includes gearbox projections  22 - 1 ,  22 - 2 ,  23 - 1 ,  23 - 2  which correspond to four related intermediate spaces between shaft projections  13 - 1 ,  13 - 2 / 14 - 1 ,  14 - 2 . The size of the gearbox projections  22 - 1 ,  22 - 2 ,  23 - 1 ,  23 - 2  is smaller than the intermediate space provided by shaft projections  13 - 1 ,  13 - 2 ,  14 - 1 ,  14 - 2 . Therefore it is enough space for rotating the neutral position  70  into fold-in position  71 . 
     Furthermore, said gearbox outer projections  23 - 1 ,  23 - 2  are formed along an circle with a bigger radius than the gearbox inner projections  22 - 1 ,  22 - 2  are positioned between radial spaces between shaft outer projections  13 - 1 ,  13 - 2 . 
       FIG. 8  shows a partial assembly drawing of upper case  90 , motor worm  82  and worm cap  120  from power fold module  30 . 
     An axis separation part  93  which is formed in the middle tier of upper case  90  is upholding the top side of motor worm  82 . A worm cap  120  which is inserted in the lower tier of upper case  90  is a separate part and is upholding the lower side of motor worm  82 . With this separation between shaft of motor  80  and shaft of motor worm  82  the initial moving noise and vibrations are removed and the driving force is decoupled when the mechanism is stopped. 
     And also the upper tier of said upper case  90  has a socket  91  which has a u-shaped form. The socket  91  hosts the motor  80  for power transmission in the upper case. The socket  91  has an equivalent size to the size of the motor  80  with the motor case  130 . 
     Motor case  130  is inserted into u-shaped socket  91 . The thickness of the u-shaped socket  91  is small to remain a flexibility for easy inserting motor case  130 . The lower tier of socket  91  has an opening  94  for the motor shaft and lower tier of the opening  94  has a bearing element  95  which is formed integrally into the body of the socket  91 . 
     The upper case forms in addition a supporter  96  for installing the worm cap bearing  122 . The supporter  96  has hook projections  97  on the outer surface for fixing worm cap  120  which functions as second bearing element for the motor worm. 
     Worm cap  120  has hooks  121  for installing and mounting the worm cap to upper case  90  by using hook projections  97 . The center of worm cap  120  forms worm cap bearing  122  which supports motor worm. 
     A motor worm  82  is installed between the bearing  95  of upper case  90  and worm cap bearing  122  of worm cap  120 . The motor worm transfers the rotation force of the motor  80  to worm wheel gear  83 . Motor worm  82  is a reduction gear in the gear drive of the power fold module. 
     Around the center of the worm cap  120  a worm cap projection  123  is formed. The worm cap projection  123  prevents the worm cap  120  to move when worm cap is installed in the upper case  90 , maintenance a pivot and prevention of torsion when mechanism is working. 
       FIG. 10  shows a sectional view of frame  110 . The frame  110  is a part of the wing mirror and hosts power fold module  30  into the mirror. 
     Frame  110  has horizontal space  112  and a vertical space  113  in the front and rear side, this spaces offer a regular matching plane when power fold module  30  is assembled and the therefore reduce assembly errors. 
     The frame  110  has a location guide  111  which formed left-right symmetry. The location guide  111  is matching to a location rib  34  of the power fold module  30 . 
     The location guide  111  has two functions: first to guide the devices during assembling, and second to reduce the motion of power fold module  30  when the mechanism is working. 
     The power fold module  30  is mounted along the arrows in  FIG. 12 . The power fold module  30  is fixed to the frame  110  using fixation holes  32  of gearbox  20  and fixation holes  115  of frame  110 . In an alternative embodiment use the module side fixation hole  33  of the gearbox  20  is used to fix the module to frame side fixation hole  116 . 
     
       
         
               
             
               
               
             
           
               
                   
               
               
                 Legend 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 10. 
                 Shaft 
               
               
                 11. 
                 Shaft projection 
               
               
                 12. 
                 Shaft flange 
               
               
                 13. 
                 Shaft inner projection 
               
               
                 14. 
                 Shaft outer projection 
               
               
                 15. 
                 Shaft inner stopper 
               
               
                 16. 
                 Shaft outer stopper 
               
               
                 17. 
                 Shaft rotative working face 
               
               
                 18. 
                 Wiring hole 
               
               
                 20. 
                 Gearbox 
               
               
                 22. 
                 Gearbox inner projection 
               
               
                 23. 
                 Gearbox outer projection 
               
               
                 24. 
                 Gearbox inner stopper 
               
               
                 25. 
                 Gearbox outer stopper 
               
               
                 26. 
                 Gearbox rotative part 
               
               
                 27. 
                 Gearbox rotative working face 
               
               
                 28. 
                 Gearbox hole 
               
               
                 30. 
                 Power fold Module 
               
               
                 32. 
                 Under fixation hole 
               
               
                 33. 
                 Side fixation hole 
               
               
                 34. 
                 Location rib 
               
               
                 40. 
                 Metal plate 
               
               
                 50. 
                 Mirror head 
               
               
                 60. 
                 Pivot 
               
               
                 70. 
                 Drive position 
               
               
                 71. 
                 Fold-in position 
               
               
                 72. 
                 Fold-over position 
               
               
                 80. 
                 Motor 
               
               
                 81. 
                 PCB 
               
               
                 82. 
                 Motor worm 
               
               
                 83. 
                 Worm wheel 
               
               
                 84. 
                 Clutch worm 
               
               
                 85. 
                 Clutch gear 
               
               
                 86. 
                 Spring 
               
               
                 87. 
                 Seal cover 
               
               
                 90. 
                 Upper case 
               
               
                 91. 
                 Socket 
               
               
                 92. 
                 Thickness of socket 
               
               
                 93. 
                 Axis separation part 
               
               
                 94. 
                 Opening 
               
               
                 95. 
                 Bearing 
               
               
                 96. 
                 Supporter 
               
               
                 97. 
                 Hook projection 
               
               
                 100. 
                 Base 
               
               
                 110. 
                 Frame 
               
               
                 111. 
                 Location guide 
               
               
                 112. 
                 Horizontal space 
               
               
                 113. 
                 Vertical space 
               
               
                 115. 
                 Frame fixation hole 
               
               
                 116. 
                 Frame side fixation hole 
               
               
                 120. 
                 Worm cap 
               
               
                 121. 
                 Hook 
               
               
                 122. 
                 Worm cap bearing 
               
               
                 123. 
                 Worm cap projection 
               
               
                 130. 
                 Motor case