Abstract:
A vehicle exterior mirror assembly includes an actuator having a case and at least two electric motors supported by a case and connected with the reflective element to provide adjustment to the reflective element with respect to at least two axes. A wiring harness is provided having a connector and a plurality of wires terminated at the connector. The connector includes at least three electrical connector terminals electrically interconnected with the wires. When the connector joins with the actuator case, the connector terminals make direct contact with corresponding receiving terminals of the electric motors. The connector preferably includes a body that is made up of two body portions that are integrally molded defining a living hinge and then folded into facing relationship thereby capturing a portion of each terminal. Complimentary retention members on the connector and actuator case retain the connector with the actuator case external of the case. The connector has a cross-section width sufficiently small to pass through the internal passage of a pivot post.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention is related to a vehicular exterior mirror assembly and, in particular, to an electrical connector arrangement for delivering electrical current to mirror positioning actuator motors in such exterior mirror assembly.  
           [0002]    Vehicle exterior mirrors are remotely positionable by an actuator assembly. Such actuator assembly typically includes two motors, each for rotating the mirror with respect to one of two generally orthogonal axes. Various techniques have been proposed for supplying electrical current to the two motors in order to independently actuate the motors in either a forward or reverse rotational direction. It is common to provide a hollow pivot post that pivotally mounts the mirror assembly to the vehicle, in order to provide a breakaway feature whereby the mirrors may be knocked out of position without damaging the mirror mounting or which may be folded by yet another motor into a foldaway position. It is known to have a wiring harness pass through the central opening of the pivot post and be terminated at one or more electrical connectors for connecting with the actuator assembly. A difficulty with the prior art is that the connector bodies used to electrically interface the wiring harness with the actuator case terminals have been too large to pass through the opening in the pivot post pivotally mounting the mirror assembly. Therefore, it has been necessary to leave the other end of the wire harness not terminated to thereby pass through the opening in the pivot post. This requires a subsequent step of terminating the other end of the wiring harness which is a labor intensive operation that must take place after the mirror has been assembled. On mirror assemblies that are not foldable, it is still necessary to pass the wires through an opening passing to the vehicle.  
           [0003]    In a proposed actuator, the connectors are made up of electrical terminals staked onto the wires and then slidably received within complimentary slots in the connector body. Such arrangement has not been entirely satisfactory. The connector body must be made relatively large in order to provide sufficient rigidity to the terminals held in this manner. Furthermore, the assembly of the terminal to the connector body is relatively labor intensive and conducive to automated assembly. Furthermore, the retention of the terminals in the connector body is of questionable strength.  
           [0004]    In order to retain the connector to the case of the actuator, resilient clips are provided on the connector body which engage openings in the actuator case. Thus, a force pushing the connector body towards the actuator case will cause the terminals of the connector to engage terminals of the case and will ultimately cause an engagement of the spring resilient clips with the openings in the actuator case. While such arrangement is intended to hold the connector in place against the actuator case, the connector can be readily dislocated by a pulling on the wire harness. Therefore, an extra stay is provided to hold the wiring harness against the actuator case to reduce the likelihood that the wires will be pulled sufficiently to dislocate the connector bodies from the case.  
           [0005]    Another difficulty with such arrangement is that it necessitates the placement of openings in the actuator case. Because the actuator is exposed to environmental conditions, namely moisture, road splash, and the like, the existence of openings in the case provides a quality difficulty with the known connector engagement mechanism. In order to overcome the difficulty, the prior art has proposed configuring the connector to provide a sealing interface between the connector body and the case. While such arrangement may reduce the amount of moisture entering the case, it cannot entirely preclude such penetration.  
           [0006]    Another difficulty with prior actuator assemblies is the necessity to provide electrical conductors from terminals on the actuator case to the electrical motors therein. It is common to use metal banding to attach the internal conductors to the external terminals which technique is prone to a high incident of poor conductivity and even mechanical failure. Several proposals have been made to replace the banding procedures of the prior art. One proposal is disclosed in commonly assigned patent application Ser. No. 08/780,996 filed Jan. 9, 1997, for a HOUSING WITH INTEGRAL CONNECTOR FOR REARVIEW MIRROR ACTUATOR ASSEMBLY, the disclosure of which is incorporated herein by reference. However, even the proposals provided therein require a separate step of applying conductors to the actuator case.  
         SUMMARY OF THE INVENTION  
         [0007]    The present invention provides a vehicular exterior mirror assembly which eliminates the drawbacks of the prior art. According to an aspect of the invention, the mirror assembly includes an actuator having a case and at least two electric motors supported by the case and connected with a reflective element to provide adjustment to the reflective element with respect to at least two axes. A wiring harness is provided having a connector and a plurality of wires terminated at the connector. The connector includes at least three electrical connector terminals electrically interconnected with the wires. When the connectors join with the actuator case, the connector terminals make direct contact with corresponding receiving terminals of the electrical motors. In this manner, the necessity for electrical connectors within the actuator casing is substantially eliminated and both motors are supplied from one connector. Importantly, this eliminates the necessity for the banding of conductors to the motor terminals and the attendant labor expenses and failure mode associated therewith. It also avoids potential misconnection resulting from use of more than one connector to feed the motors.  
           [0008]    According to another aspect of the invention, a vehicular exterior mirror assembly includes an actuator having a case and at least two electric motors supported by the case and connected with a reflective element to provide adjustment to the reflective element with respect to two axes. A wiring harness is provided having a connector and a plurality of wires terminated at the connector. The connector includes a plurality of electrical connector terminals electrically interconnected with the wires and adapted to be joined with the actuator case. The connector includes a body defined by two facing portions that capture portions of the connector terminals between the two facing portions. This configuration provides exceptionally secure mechanical support for the terminals by the connector body. This is accomplished in a manner which is easy to assemble and is adapted to automatic assembling techniques. In particular, the connector terminals may be supported by application from above one of the facing portions with the other facing portion then being placed above the connector terminals thereby holding the terminals in place. Preferably, the two portions are integrally molded and define a living hinge. The portions may be joined in facing relationship by known techniques, such as cold staking, heat staking, snap welding, sonic welding and adhesive bonding.  
           [0009]    According to another aspect of the invention, a vehicular exterior mirror assembly includes an actuator having a case and at least two electric motors supported by the case and connected with a reflective element to provide adjustment to the reflective element with respect to the two axes. A wiring harness is provided having a connector and a plurality of wires terminated at the connector. The connector includes a plurality of electrical connector terminals electrically interconnected with the wires and adapted to be joined with the actuator case. Complimentary retention members on the connector and the actuator case engage to retain the connector with the actuator case. The retention members are positively engaged, thus requiring motion other than a separating motion between the connector and the actuator case to disengage the retention members. This provides an exceptionally strong mechanical bond between the connector and the actuator case. Preferably, the retention member includes a pair of ears on one of the connector and the actuator case which engage features protruding from the other of the connector and the actuator case.  
           [0010]    Accordingly to yet another aspect of the invention, a vehicular exterior mirror assembly includes an actuator having a case and at least two electrical motors supported by the case and connected with a reflective element to provide adjustment to the reflective element with respect to at least two axes. The assembly further includes a wiring harness having a connector and a plurality of wires terminated at the connector. The connector includes a plurality of electrical connector terminals electrically interconnected with the wires and adapted to be joined with the actuator case. The mirror assembly housing defines an internal passage therethrough. The electrical connector has a cross-section width dimension that is less than the cross section of the internal passage of the mirror assembly housing. This allows the connector to be passed through the opening during assembly of the mirror assembly. In this manner, both ends of the wiring harness can be terminated in electrical connectors prior to assembly to the mirror assembly and the connector which joins with the actuator case can be passed through the opening in order to interconnect the actuator with the vehicle electrical system. This is exceptionally efficient in assembly of the mirror assembly. By allowing both ends of the wiring harness to be terminated in connectors ahead of time, the wiring harness is adapted to be manufactured using automated techniques.  
           [0011]    These and other objects, advantages, and features of this invention will become apparent upon review of the following specification in conjunction with the drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is a rear elevation looking forward with respect to the vehicle, of an exterior mirror assembly according to the invention, with a portion of the reflective element removed to reveal internal features thereof;  
         [0013]    [0013]FIG. 2 is an exploded perspective view of an actuator and wiring harness according to the invention;  
         [0014]    [0014]FIG. 3 is a bottom plan view of an actuator illustrating features of the case which are engageable with a wiring harness according to the invention;  
         [0015]    [0015]FIG. 4 is a top plan view of an actuator with a portion of the case removed to reveal internal features thereof;  
         [0016]    [0016]FIG. 5 is a side elevation taken along the lines V-V in FIG. 4;  
         [0017]    [0017]FIG. 6 is the same view as FIG. 3 with a wiring harness and connector attached to the actuator case;  
         [0018]    [0018]FIG. 7 is a sectional view taken along the lines VII-VII in FIG. 6;  
         [0019]    [0019]FIG. 8 is a perspective view of a wiring harness according to the invention;  
         [0020]    [0020]FIG. 9 is an end elevation taken along the lines IX-IX in FIG. 8;  
         [0021]    [0021]FIG. 10 is a sectional view taken along the lines X-X in FIG. 8;  
         [0022]    [0022]FIG. 11 is an end elevation taken along the lines XI-XI in FIG. 8;  
         [0023]    [0023]FIG. 12 is the same view as FIG. 11 illustrating the portions of the connector in their unassembled position for receiving electrical terminals therein; and  
         [0024]    [0024]FIG. 13 is a view taken along the lines XIII-XIII in FIG. 12. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0025]    Referring now specifically to the drawings, and the illustrative embodiments depicted therein, a vehicular exterior mirror assembly  20  includes an actuator  22 , which is mounted by a bracket  24  through a pivot post  26  to a portion  28  of a vehicle (FIG. 1). A mirror reflective element  30  is supported by actuator  22  in a manner that provides adjustability to the plane of the mirror element about two axes which are generally aligned with earth&#39;s vertical and horizontal axes (not shown). Mirror element  30  may be an electro-optic mirror element capable of a partial reflectance level such as an electrochromic mirror element or may be a non-electro-optic mirror element, such as a chrome mirror or the like. Pivot post  26  provides a breakaway feature of mirror assembly  20  such that engagement with a fixed or moveable object will tend to result in folding of the mirror forwardly and rearwardly rather than destruction of the mirror. However, pivot post  26  could also provide a foldaway feature to mirror assembly  20  such that the mirror assembly can be folded close to the vehicle body by a motor (not shown) in response to actuation by an actuator as is known in the art. A housing  32  generally surrounds actuator  22  and bracket  24  and is also attached to pivot post  26  or to bracket  24 . Pivot post  26  is hollow including a through-opening  27  through its pivot axis.  
         [0026]    Actuator  22  includes a case  34  made up of complimentary case portions  36   a  and  36   b  (FIG. 2). A mirror mounting flange  40  is pivotally positionable with respect to case  34  in a manner which is described in copending application Ser. No. 09/047,846 filed Mar. 25, 1998, by Robert E. Schnell for a PIVOT SUPPORT FOR ADJUSTABLE REARVIEW MIRROR, the disclosure of which is hereby incorporated herein by reference. Suffice it to say, mounting flange  40  includes an outer conical surface (not shown) on a portion  42  which is in slidable contact with an edge  46  defined by a generally cylindrical wall  48  of case portion  36   b . Mirror mounting flange  40  is biased into moveable engagement with case  34  by a fastener  50  and spring biasing member  52  which biases a retention cup  54  in the direction of case  34  by engagement with a post  56  extending from case portion  36   b.    
         [0027]    Mirror mounting flange  40  is rotated independently about two generally orthogonal axes by a pair of screw jacks  58 . Each screw jack has a ball  60  which is received within a socket (not shown) of mirror mounting flange  40  and a threaded shaft  62  which threadably engages an internal thread  80  of a rotatable nut member  64 . An opening  66  through which screw jack  58  extends is sealed by a gasket member  68  having a seal  70  overlying opening  66 . Each seal  70 , in turn, has an opening  72  through which ball  60  can protrude. Each nut member  64  includes an external ring  74  having gear teeth formed thereon which is rotatably engaged with a worm gear  76  of an electric DC motor  78 . In this manner, rotation of worm gear  76  by motor  78  rotates nut member  64  which extends or retracts screw jack  58  by threadable engagement between threaded shaft  62  and internal threads  80  on nut member  64 . Although the above is a preferred mechanism for pivotably positioning the mirror mounting flange with respect to the case, other mechanisms known in the art may also be used.  
         [0028]    If mirror assembly  20  is a memory mirror which is capable of being repositioned to positions stored in a memory device, as is known in the art, actuator  22  may additionally include a pair of linear position transducers  81 . In the illustrated embodiment, transducers  81  are made up of an actuator  82  which slidably engages a set of carbon traces (not shown) on a circuit board  84  mounted to case portion  36   a . In this manner, as each motor  78  positions mirror mounting flange  40  about its associated axis, the position of the mirror-mounting flange with respect to that axis is monitored by the corresponding linear position transducer  81 . The details of linear transducers  81  are disclosed in detail in application Ser. No. ______ filed concurrently with the present application by David Willmore and Robert Schnell for a VEHICLE MEMORY MIRROR POSITION TRANSDUCER (Attorney Docket No. DON01 P-687), the disclosure of which is hereby incorporated herein by reference. However, other forms of position transducers known in the art may be used if a memory mirror function is desired. Movable components of actuator  22  may be lubricated with a suitable lubricant, such as a synthetic hydrocarbon with lithium soap marketed by NYE Lubricants under Model No. Rheolube 361, or the like.  
         [0029]    Motors  78  each include a pair of female terminals  86  which supply electrical energy to operate motors  78  (FIGS.  4 - 7 ). In the illustrated embodiment, terminals  86  are recessed female terminals but could, alternatively, be male terminals protruding from the housing of motors  78 . Housing portion  36   a  has an outer surface  88  which defines a connector-engaging portion  90 . A series of openings  92  are formed in connector-engaging portion  90 . Openings  92  are generally aligned with terminals  86  such that a male terminal inserted in an opening  92  will engage a corresponding female terminal  86 . Connector-engaging portion  90  has a pair of side portions  94   a  and  94   b , each of which extends generally at right angles to connector-engaging portion  90  of outer surface  88 . A pair of retention members  96   a ,  96   b  protrude from respective side portions  94   a ,  94   b . Each retention member includes a camming surface  98   a ,  98   b  and a retention surface  100   a ,  100   b.    
         [0030]    Mirror assembly  20  further includes a wire harness  102  which is made up of a plurality of wires  104 , each of which is electrically and mechanically joined with an electrical terminal  106  of a connector assembly  108 . Connector assembly  108  includes a body  110  made up of two facing body portions  112   a ,  112   b . Body portion  112   a  includes a plurality of recesses  114  which are configured to conform to a base portion  107  of terminal  106 . Each recess is juxtaposed with an opening  109  that penetrates body portion  112  such that the terminal  106  may extend from the connector body. Each terminal base portion  107  is inserted into one of the recesses  109  and retained therein when the body portion  112   b  is joined with body portion  112   a . This is accomplished by joining the body portions by known relationships, such as cold staking, heat staking, snap welding, sonic welding, adhesive bonding, or the like. To assist in the bonding, one or more posts  116  extend from either body portion  112   a  or  112   b  and are tightly received in a corresponding opening  118  in the opposite body portion  112   a ,  112   b . Post  118  provides an additional surface area for use in joining the connector portions together and may be deformed during the joining process to further retain the body portions together. As can be seen by reference to FIG. 9, because each contact base portion  107  is captured between body portion  112   a  and  112   b , the terminal is resistant to being pulled out of its mooring in the connector. Advantageously, body portions  112   a  and  112   b  may be formed together in a single piece by a living hinge including a hinge portion  120  such that, prior to assembly, the body portions  112   a  and  112   b  are generally coplanar, as illustrated in FIGS. 12 and 13, and, after assembly, the body portions are in facing relationship, as illustrated in FIGS.  8 - 11 . In the illustrated embodiment, body  110  is made from polyester plastic but other known plastics may be used.  
         [0031]    A pair of retention members  115 , shown as ears, extend from body portion  108  and engage with respective retention members  96   a  and  96   b  on case portion  36   a . Each retention member  115  has an outer frame  113  surrounding a central opening  114  therein. The solid frame  113  of retention member  115  slides over respective camming surfaces  98   a ,  98   b  as connector assembly  108  is joined with casing  36 . Because retention members  115  are flexible, they expand outward under the action of camming surfaces  98   a ,  98   b  and may be captured by retention surface  100  thereby mechanically retaining the connector in position against casing  36 . Retention members  115  may be made resilient so that they snap into alignment with retention surfaces  100 . Alternatively, they could be flexible yet require movement into position with retention surfaces  100   a ,  100   b  either by finger motion or by using a tool. However, it is seen that the engagement between retention members  115  and retention members  96   a ,  96   b  provide complimentary retention members which positively retain a connector on the actuator case such that the connector is not prone to being pulled off of the case merely by pulling on wires  104 . Instead, a positive disengagement motion on retention members  115  is required in order to remove the connector from the case. The retention members could be configured such that a tool is required to dislodge the ears from the retention member. Alternatively, they could be configured that finger motion is all that is necessary to dislodge the retention members. Either way, the engagement between the connector assembly and the case is secure. It should be apparent that retention members  115  could be positioned on case  34  and retention members  96   a ,  96   b  on connector body  108 .  
         [0032]    Connector body  108  has a maximum cross-sectional dimension D shown in FIG. 10 that is perpendicular to its long axis A seen in FIG. 8. In this manner, connector assembly  108  can be fit through a circular opening having a diameter at least somewhat greater than the dimension D. Because of the unique configuration of connector  108 , dimension D can be made smaller than cross-section dimensions of central opening  27  through pivot post  26  so that connector assembly  108  can be fit through central opening  27  of pivot post  26 . This allows wiring harness  102  to be fully assembled to connector  124  on the opposite ends of wires  104  prior to assembly of the exterior mirror assembly. This advantageously allows the wiring harness to be inserted in position extending from vehicle portion  28  to actuator  22  through pivot post  26  after both ends of wiring harness  102  are terminated with connectors. This is advantageous during assembly of the vehicle exterior mirror assembly because wiring harness  102  may be assembled to the mirror assembly after it has been assembled merely by the insertion of connector assembly  108  through the opening in pivot post  26  without the need for subsequent termination of individual wires  104 .  
         [0033]    Connector assembly  108  has, preferably, four terminals for individually connecting to both motors  78 . Two of the terminals can, if desired, be fed by a common ground or power lead. Alternatively, connector  108  could have three terminals for connecting with both motors  78 , one of the terminals being a common ground or a common power lead to both motors. Advantageously, this simultaneous connection to both motors  78  reduces the number of connections that must be made during assembly of the vehicle and reduces the ability to misconnect the wiring harness to the actuator. Advantageously, connector assembly  108  is retained to case  36  by retention members that do not penetrate the case. Because every opening into the case is a potential source of moisture leakage, this feature enhances the moisture resistance of the actuator case. Because terminals  106  connect directly with terminals on the motor, the need for an internal wiring harness in case  36  is eliminated.  
         [0034]    Connector assembly  108  securely retains terminals  106  in the connector body by retaining a base  107  of each terminal  106  between opposing housing portions which are fixedly joined together. This greatly enhances the securing of each terminal within the connector. Furthermore, because the terminals are inserted through openings in a connector portion, the connector is adapted to automated assembly techniques.  
         [0035]    Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.