Patent Abstract:
An interior rearview mirror assembly for a vehicle includes a mirror head, a mounting base, a support arm and a cover element. The mirror head includes a reflective element and at least one electronic component which is electrically connected to a power source of the vehicle via wiring. The support arm has an elongated shaft portion, a first end and a second end opposite said first end. The mirror head is pivotable about the first end via a first ball and socket joint, and the second end is pivotable about the mounting base via a second ball and socket joint. The wiring is disposed between an outer surface of the shaft portion and the cover element. The cover element attaches to the shaft portion such that the wiring is routed at least partially along the outer surface and is at least partially hidden from view by the cover element.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   The present application is a continuation of U.S. patent application Ser. No. 10/397,599, filed Mar. 26, 2003, now U.S. Pat. No. 6,983,920, which is a divisional application of U.S. patent application Ser. No. 09/470,791, filed Dec. 23, 1999 by DeLine for REAR VIEW MIRROR MOUNTING ASSEMBLY, now U.S. Pat. No. 6,540,193, the disclosures of which are hereby incorporated by reference herein. 

   BACKGROUND OF THE INVENTION 
   The present invention relates generally to a rearview mirror mounting assembly and, more particularly, to a rearview mirror mounting assembly which pivotally mounts an interior rearview mirror to a mounting base attached to the vehicle. 
   Mounting brackets for supporting rearview mirrors are well known in the art. Typically, a rearview mirror is mounted to a mounting base via one or more ball and socket connections or joints. The double jointed mounting bracket allows for further movement of the interior rearview mirror relative to the mounting base, which is typically secured to an interior surface of the windshield of the vehicle or to a headliner or console at an upper edge of the windshield. The bracket must tightly retain a ball within the socket of the ball and socket joint, while still allowing relative rotation or pivoting therebetween. If the joints are not tightly secured, the interior rearview mirror may experience excessive vibration when the vehicle is being driven. These vibrational concerns are further enhanced when the interior rearview mirror comprises multiple components and electronic circuitry, such as electrochromic reflectors, microphones, map reading lights, and/or other accessories, which may add to the weight of the interior rearview mirror. These accessories increase the weight of the mirrors, such that the mirrors are not stable with a conventional double ball and socket-mounting bracket. 
   It is known to implement larger sized ball and socket joints to provide increased friction and thus greater stability between the ball and socket members of the mounting bracket. The larger ball further allows for a larger neck on the mounting bracket to increase bending inertia of the bracket. At the same time, however, it is preferred to minimize the size of the bracket components to enhance the appearance of the mirror assembly. 
   In order to provide a tight grip on the ball member, a spring or other biasing member may be implemented within a support arm of the mounting assembly in order to increase the gripping or clamping of the ball by the socket portion of the assembly. The spring is typically mounted and secured within the arm such that the spring exerts a force on the socket portion, which causes the socket to partially compress about the ball. A raised portion or ridge on the socket portion is provided which extends partially within the center of the spring, in order to properly align the spring within the mounting arm. The spring thus has to have a sufficient diameter to receive the raised portion within the coils of the spring. 
   These operational aspects of rearview mirror supports illustrated a need for supporting higher weight, added feature rearview mirrors while minimizing vibration, and for reducing functional problems in mirror supports such as misaligned springs, all while maintaining a pleasing overall appearance. 
   SUMMARY OF THE INVENTION 
   The present invention is intended to provide a mirror mounting assembly which pivotally mounts an interior rearview mirror to a mounting base positioned on the vehicle. Preferably, the mirror is mounted or connected to the mounting base via a dual ball and socket joint, at least one of which comprises a ball receiving cavity which pivotally receives a ball member therein. The ball receiving cavity maintains a secure grip on the ball member via a biasing member which is aligned and contained within a sleeve of the mounting assembly. The present invention is preferably implemented with an interior rearview mirror which comprises one or more electrical accessories and is thus of a greater weight than a standard mirror. For example, the mirror may weigh approximately 300 grams and may even weigh greater than approximately 500 grams. 
   According to a first aspect of the present invention, a support bracket for pivotally securing an accessory to a vehicle comprises a mounting base and a mounting arm. The mounting base is adapted for mounting to the vehicle. The mounting arm is pivotally securable to at least one of the mounting base and the accessory. The mounting arm comprises at least one ball receiving socket, a biasing member, an alignment element for aligning the biasing member. The alignment element comprises an outer confinement member which engages at least a portion of an outer surface of the biasing member. Preferably, the mounting arm further comprises a sleeve which at least partially encases the ball receiving socket and the biasing member. The ball receiving socket pivotally receives a ball member of one of the mounting base and the accessory. The confinement member extends at least partially along the biasing member to align the biasing member within the sleeve such that the biasing member biases the ball receiving socket toward the ball member, thereby pivotally securing the ball member therein. 
   Preferably, the confinement member comprises an annular ring. Preferably, the alignment element further comprises a substantially planar surface at a base of the confinement member, whereby an end of said biasing member engages the planar surface. Preferably, the sleeve is narrowed at an end corresponding to the ball receiving socket. The narrowed end is operable to clamp the ball receiving socket about the ball member in response to the biasing member biasing the socket toward the narrowed end of the sleeve. Preferably, a second ball member is rigidly secured at an end of the sleeve opposite the narrowed end. A base portion of the second ball member comprises the alignment element to align the biasing member between the ball receiving socket and the second ball member. 
   In one form, the biasing member is a coil spring which engages a planar, recessed region in the ball receiving socket. In another form, the biasing member is unitarily formed with the ball receiving socket and compressibly engages a recessed region at one of a ball receiving socket of the mounting arm, a ball member of the mounting arm, and the mirror itself. 
   According to another aspect of the present invention, a support bracket pivotally secures an accessory to the vehicle. The accessory has at least one electronic component which is electrically connected to a vehicle wiring via an accessory wiring. The support bracket comprises a mounting base and a mounting arm. The mounting base is adapted for mounting to the vehicle and comprises a first ball receiving socket. The mounting arm pivotally secures to the mounting base and to the accessory. The mounting arm comprises a first ball member for pivotally engaging the first ball receiving socket and a second ball member for pivotally engaging a second ball receiving socket on the accessory. The first ball member is positioned at an opposite end of the mounting arm from the second ball member. The mounting arm further comprises an outer sleeve which at least partially encases the mounting arm and the accessory wiring. 
   Therefore, the present invention provides a support assembly which provides pivotable mounting of an accessory or mirror relative to a mounting base. The alignment of the biasing member is maintained via at least one confinement member, such as an annular guide which extends along the arm of the support assembly, which substantially precludes lateral movement of the biasing member relative to the support assembly. A second ball member of the support assembly may be rigidly secured to the sleeve to further reduce vibration of the mirror. The first and second ball members may comprise the same sized ball or may have different diameter ball members. For example, the second ball member of the support assembly may have a greater diameter than the first ball member of the mounting base. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view looking forwardly in a vehicle of a rearview mirror mounting assembly in accordance with the present invention; 
       FIG. 2  is a sectional side view of the mounting assembly of  FIG. 1 ; 
       FIG. 3A  is a perspective view of a ball receiving socket showing the ball receiving portion of the socket; 
       FIG. 3B  is a perspective view of the opposite end of the socket of  FIG. 3A , showing the alignment ring and surface for the biasing member; 
       FIG. 4  is a sectional side view of an alternate embodiment of the present invention; 
       FIG. 5  is a sectional end view of the mounting arm, taken along the line V-V in  FIG. 4 ; 
       FIG. 6  is a sectional side view of another alternate embodiment of the present invention wherein the ball receiving socket further comprises the biasing member; 
       FIG. 7  is a perspective view of the ball receiving socket shown in  FIG. 6 ; 
       FIG. 8  is a sectional side view of another alternate embodiment of the present invention, wherein the mounting arm is fixedly secured to the interior rearview mirror; 
       FIG. 9  is a perspective exploded view of another alternate embodiment of the present invention; 
       FIG. 10  is a sectional end view of a mounting arm and plastic cover, taken along the line X-X in  FIG. 9 ; and 
       FIG. 11  is a side elevation of another embodiment of the bracket assembly of  FIG. 9 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring now specifically to the drawings, and the illustrative embodiments depicted therein, an accessory or interior rearview mirror  10  is pivotally mounted to a mounting assembly  12 , which comprises a mounting arm  14 , which is pivotally mounted to a mirror mount or mounting base  16  ( FIG. 1 ). Mounting arm  14  of mounting assembly  12  preferably comprises a ball receiving member  20 , a biasing member  22 , a second ball member  24  and a sleeve member  26  which at least partially encases ball receiver  20 , biasing member  22 , and second ball member  24  ( FIG. 2 ). Preferably, biasing member  22  is positioned and aligned between ball receiver  20  and second ball member  24  and functions to bias ball receiver  20  outwardly from second ball member  24  and biasing member  22 , such that ball receiver  20  grips ball member  16   b , as discussed in detail below. Biasing member  22  is aligned longitudinally along sleeve  26  between ball member  24  and ball receiver  20  via a confining member, such as a raised annular ring  20   f , which is preferably at least partially cylindrical in section, and/or a corresponding confining member or annular ring  24   d , which extend longitudinally from a respective base or generally planar surface  20   e  and/or  24   f  at either or both of ball receiver  20  and/or ball member  24 , respectively, as discussed below. 
   The interior rearview mirror  10  may be a conventional electrochromic or prismatic day/night interior mirror and may comprise additional electronic components, such as map reading lights, a speaker and/or microphone, which may be in the mirror or within a module attached to the mirror or mounting arm as disclosed in commonly assigned U.S. patent application, Ser. No. 09/382,720, filed Aug. 25, 1999, now U.S. Pat. No. 6,243,003, an indicator for the microphone of the type disclosed in commonly assigned U.S. patent application, Ser. No. 09/396,179, filed Sep. 14, 1999, now U.S. Pat. No. 6,278,377, displays, such as of the type disclosed in commonly assigned U.S. patent application, Ser. No. 09/448,700, filed Nov. 24, 1999 by Timothy G. Skiver, Joseph P. McCaw, John T. Uken, and Jonathan E. DeLine for REARVIEW MIRROR ASSEMBLY WITH ADDED FEATURE MODULAR DISPLAY, now U.S. Pat. No. 6,329,925, communication systems, which may comprise a processing system of the type disclosed in commonly assigned U.S. patent application, Ser. No. 09/466,010, filed Dec. 17, 1999 by Jonathan E. DeLine, Niall R. Lynam, Ralph A. Spooner and Philip A. March for INTERIOR REARVIEW MIRROR SOUND PROCESSING SYSTEM, now U.S. Pat. No. 6,420,975, and/or the like, all of the disclosures of which are hereby incorporated herein by reference. Additionally, the interior rearview mirror may comprise storage capabilities, such as disclosed in commonly assigned U.S. patent application, Ser. No. 09/449,121, filed Nov. 24, 1999, now U.S. Pat. No. 6,428,172, and/or a compartment for electrical accessories, such as disclosed in commonly assigned U.S. patent application, Ser. No. 09/433,467, filed Nov. 4, 1999, now U.S. Pat. No. 6,326,613, and/or the like, the disclosures of which are hereby incorporated herein by reference. Because the rearview mirror may comprise one or more electrical accessories and may function to store other items, the mirror may have a greater weight than a standard prismatic mirror. Preferably, support assembly  12  supports an interior rearview mirror  10  weighing at least approximately 300 grams. More preferably, support assembly  12  supports an interior rearview mirror  10  which weighs at least approximately 400 grams and most preferably, at least approximately 500 grams. 
   The mount  16  may be secured, such as by an adhesive, to an interior surface  18   a  of a vehicle windshield  18  ( FIG. 2 ) and may be a conventional mounting button, channel mount, a base member of the type disclosed in commonly assigned U.S. Pat. No. 4,936,533, issued to Adams et al., the disclosure of which is hereby incorporated herein by reference, or a breakaway mount of the type disclosed in commonly assigned U.S. Pat. No. 5,820,097, issued to Spooner, or U.S. Pat. No. 5,100,095, issued to Haan, et al., the disclosures of which are hereby incorporated herein by reference. 
   Preferably, as shown in  FIG. 2 , mounting base  16  of mounting assembly  12  is secured to a mounting plate  16   a  (commonly referred to in the art as a mirror mounting button), which is secured to interior surface  18   a  of the windshield  18 . Mounting plate  16   a  may be secured to the interior surface of the windshield, such as by an adhesive, or may be secured to a headliner or console (not shown) at or adjacent to an upper edge of the windshield, without affecting the scope of the present invention. Mounting base  16  preferably comprises a ball member  16   b  formed at an end of a neck portion  16   c  extending outwardly and rearwardly from a base portion  16   d  of the mount  16 . Ball member  16   b  and neck  16   c  are preferably integrally formed with base  16   d  and may comprise a metal, such as aluminum, such as A-380 aluminum, which may be powder painted to color match mount  16  with the trim and/or mirror housing of the vehicle. However, it is further envisioned that ball member  16   b  may comprise an engineering polymer, such as a filled polymer, such as glass or mineral filled Nylon or the like, without affecting the scope of the present invention. Ball member  16   b  is a generally spherical shaped ball for pivotal engagement with a correspondingly formed receiving socket on mounting arm  14 , as discussed below. Preferably, the ball  16   b  and neck portion  16   c  are partially hollowed or cored to reduce the mass of the mounting assembly  12 . Although not critical to the present invention, the mount  16  may be secured to the base portion  16   a  via a set screw  16   e , as shown in  FIG. 2 , or via any other known mounting means, and may be a breakaway mount or any other mount secured to a headliner or console of the vehicle, without affecting the scope of the present invention. 
   As shown in  FIGS. 1 and 2 , sleeve  26  is a generally cylindrical member which extends between mount  16  and interior rearview mirror  10 . Preferably, sleeve  26  comprises a metal tubing, such as an aluminum tubing, such as aluminum 6061T9, which may be powder coated to match the color of the mount  16  and/or interior rearview mirror  10  and/or a desired vehicle interior or trim. However, other materials, such as an engineering polymer, such as a filled polymer, such as glass or mineral filled Nylon or the like, may be implemented without affecting the scope of the present invention. Sleeve  26  is generally hollow and comprises a cylindrical side wall  26   d  which defines an inner surface  26   f  and encases ball receiver  20 , biasing member  22 , and a portion of second ball member  24 , as discussed below. Sleeve  26  is preferably tapered or narrowed toward a forward end  26   a  and further comprises an inwardly curved end  26   b , which is generally longitudinally opposite from tapered end  26   a . Inwardly turned end  26   b  is sharply curved radially inwardly to form a generally annular ridge or ring  26   c , which closes a portion of the rearward end  26   b , such that the end  26   b  has a smaller diameter opening than the cylindrical side walls  26   d  of sleeve  26 . 
   As shown in  FIGS. 2 ,  3 A, and  3 B, ball receiver  20  preferably comprises a base portion  20   a  and a ball receiving portion  20   b . Ball receiving portion  20   b  comprises a cylindrical side wall  20   c  and a partially spherical inner surface  20   d . Cylindrical side wall  20   c  extends longitudinally outwardly from spherical surface  20   d  of base portion  20   a , and defines a ball receiving cavity or socket for pivotally receiving ball member  16   b  of mount  16 . Cylindrical side wall  20   c  and base portion  20   a  slidably engage inner surface  26   f  of sleeve  26  as ball receiver  20  is moved by biasing member  22 . Preferably, ball receiving socket  20  comprises an elastomeric material, such as polypropylene or the like, such that cylindrical wall  20   c  may flex radially inwardly as ball receiver  20  is moved longitudinally toward tapered end  26   a  of sleeve  26 . Preferably, as best shown in  FIG. 3A , cylindrical side wall  20   c  further comprises a plurality of notches  20   g  which extend longitudinally from a forward end  20   h  of ball receiver  20 . Notches  20   g  facilitate substantially uniform compression of forward end  20   h  of ball receiver  20  as forward end  20   h  is compressed radially inwardly by tapered end  26   a  of sleeve  26 , in response to a biasing force exerted on ball receiver  20  toward tapered end  26   a  by biasing member  22 . A circumferential groove or channel  20   j  may be formed around an outer circumferential edge of partially spherical surface  20   d  and radially inwardly of cylindrical side walls  20   c , to further facilitate inward bending of cylindrical walls  20   c  as the walls  20   c  engage tapered end  26   a  of sleeve  26 . 
   Base portion  20   a  of ball receiver  20  defines partial spherical surface  20   d  at one end and further defines the means or element for aligning and guiding biasing member  22  at an end opposite the partial spherical surface  20   d . Base portion  20   a  of ball receiver  20  comprises a substantially planar center region  20   e  and a raised or longitudinally extending annular, cylindrical outer region  20   f . Raised annular outer portions  20   f  form a cylindrical side wall or guide around an outer circumferential edge of planar surface  20   e , thereby defining a recessed, biasing member receiving portion of receiver  20 . A forward end  22   a  of biasing member  22  is then received by the recessed portion and thereby aligned and secured within sleeve  26  by guide walls  20   f.    
   Second ball member  24  comprises a spherical shaped ball portion  24   a , a base portion  24   b , and a neck region  24   c  extending between base portion  24   b  and ball  24   a . Ball portion  24   a  is positioned at an outer or rearward end of neck  24   c , which extends from base portion  24   b , such that ball  24   a  and neck  24   c  extend outwardly from end  26   b  of sleeve  26  in a direction generally rearwardly with respect to the vehicle. Preferably, ball  24   a , neck  24   c  and base  24   b  are unitarily constructed and may be hollowed or cored in either direction to hollow out ball  24   a  and neck  24   c  to reduce the weight of the assembly. Ball member  24  may be substantially hollowed or cored from the forward end, as shown in  FIG. 2 , or may be cored from the rearward end of ball  24   a , as shown in  FIG. 6 . Preferably, ball member  24  comprises a metal, such as aluminum, such as a die cast aluminum, which may be powder painted to match the color with sleeve  26  and/or mount  16  and/or the vehicle interior. However, it is further envisioned that other materials, such as an engineering polymer, such as a filled polymer, such as glass or mineral filled Nylon or the like, may be implemented without affecting the scope of the present in invention. 
   Base portion  24   b  is preferably correspondingly formed with inwardly curved end  26   b  of sleeve  26  and is positioned within sleeve  26  such that an outer shoulder  24   e  of base portion  24   b  engages annular ring  26   c  of sleeve  26 , thereby substantially precluding second ball member  24  from moving longitudinally outwardly from sleeve  26 . Preferably, ball member  24  is rigidly secured within sleeve  26 , such as by welding the shoulder portion  24   e  to curved end  26   b  of sleeve  26 , or by any other known means for securing the two components together. Alternately, the second ball member  24  may be unitarily formed with sleeve  26 , without affecting the scope of the present invention. Base portion  24   b  of ball member  24  further comprises an outer confining member or annular ring  24   d  which extends longitudinally within sleeve  26  along the cylindrical side walls  26   d , in a direction generally opposite from neck  24   c . Annular ring or wall  24   d  defines and encircles a generally planar, annular ring or surface  24   f  formed at base portion  24   b , such that a rearward end  22   b  of biasing member  22  engages surface  24   f  and is received within the recess formed by ring  24   d  and planar surface  24   f . Although shown as an annular, ring shaped surface, planar surface  24   f  may otherwise be a substantially continuous surface if ball member  24  is not cored or hollowed, or if ball member  24  is cored from the opposite end, such as is shown in  FIG. 6 . 
   Biasing member  22  is preferably a coil spring, such as a steel spring having a spring rate of approximately 650 N/mm, although other materials and/or spring rates may be implemented without affecting the scope of the present invention. Biasing member  22  extends longitudinally within sleeve  26  and between the planar surfaces  20   e  and  24   f  of ball receiver  20  and ball member  24 , respectively. Biasing member  22  is secured and aligned between the two components by the annular rings  20   f  and  24   d , which extend longitudinally toward one another from the respective components  20  and  24 . The annular flanges or walls  20   f  and  24   d  function to align and laterally confine biasing member  22 , such that opposite ends  22   a  and  22   b  of biasing member  22  engage the substantially planar surfaces  20   e  and  24   f  of ball receiver  20  and ball member  24 , respectively. Lateral or radial movement of biasing member  22  is thus substantially precluded by rings or walls  20   f  and  24   d  engaging an outer surface  22   d  of biasing member  22 . 
   Accordingly, ball receiver  20  receives ball member  16   b  of mount  16 , such that arm  14  is pivotally secured to mount  16 . Second ball member  24  likewise engages a correspondingly formed ball receiver or socket (not shown) of interior rearview mirror  10 , such that interior rearview mirror  10  is also pivotally mounted to mounting arm  14  of mounting assembly  12 . Biasing member  22  is partially compressed when mounting arm  12  is assembled and engaged with ball member  16   b  of mount  16 , such that biasing member  22  exerts a force longitudinally along sleeve  26  toward ball receiver  20 . Because second ball member  24  is substantially fixed relative to sleeve  26 , rearward end  22   b  of biasing member  22  is also substantially fixed relative to sleeve  26 . Cylindrical side walls  20   c  of ball receiving portion  20   b  are then forced inwardly at tapered end  26   a  of sleeve  26 , such that ball receiver  20  grips ball member  16   b  on mount  16  in response to the biasing force exerted by biasing member  22 . Further longitudinal movement of ball receiver  20  is limited as outer end  20   h  of cylindrical wall  20   c  becomes wedged between sleeve  26  and ball  16   b , since the diameter of ball  16   b  and cylindrical wall  20   c  is greater than the narrowed opening of narrowed end  26   a  of sleeve  26 . The desired level of gripping of ball  16   b  by socket  20   b  may be attained by selecting an appropriate spring rate for biasing member  22  or by altering the coefficient of friction of ball receiver  20 . 
   Because arm  14  comprises a ball-in (ball receiver  20  of arm  14  receives ball member  16   b ) and a ball-out (ball member  24  extends outwardly from arm  14 ) mounting arrangement, mounting arm  14  provides a shorter overall length, such that the pivot joints of the mounting assembly  12  are closer to the main support or mount  16 , thereby reducing vibration of the mirror mount assembly. Furthermore, because ball member  24  is rigidly secured to or formed with the sleeve  26  of arm  14 , there is less vibration in the mounting arm assembly. Ball  24   a  of ball member  24  may be the same size as ball  16   b  of mount  16 , or may be of a greater diameter to enhance gripping within the corresponding receiving socket of the mirror, which further reduces vibration of the rearview mirror. Preferably, ball  24   a  has a greater diameter than ball  16   b . More preferably, ball  24   a  has a diameter which is greater than approximately 20 mm, such as approximately 22.4 mm, while ball  16   b  has a diameter which is less than approximately 20 mm, such as approximately 15 mm. Alternatively, however, the ball  24   a  of ball member  24  may have a smaller diameter than the ball  16   b  of mount  16 , without affecting the scope of the present invention. 
   Additionally, the present invention allows a smaller diameter spring to be implemented between the ball member  24  and ball receiver  20 , while still maintaining proper alignment therebetween, since the longitudinally extending cylindrical side walls of ball receiver  20  and ball member  24  substantially preclude radial or lateral movement of biasing member  22  with respect to sleeve  26 . A center ridge or bump on the ball receiver and/or the ball member to insert within the spring is not necessary to align the spring within the mounting arm. This approach further allows for ball member  24  to be cored out from its rearward end, as shown in  FIG. 6 , or its forward end, as shown in  FIGS. 2 and 4 , while still providing proper alignment of biasing member  22 , all of which reduces weight and vibration in the assembly. 
   Referring now to  FIGS. 4 and 5 , an alternate support bracket assembly  112  is shown, which comprises a mount  16  and an arm  114 . Mount  16  is substantially identical to mount  16  discussed above with respect to support assembly  12 , such that a detailed discussion of mount  16  will not be repeated herein. Arm  114  is likewise substantially similar to arm  14 , discussed above, in that it comprises a sleeve  126 , which substantially encases a ball receiving portion  20 , a biasing member  22 , and a second ball member  24 . Ball receiving portion  20 , biasing member  22 , and second ball member  24  are also substantially similar to the components discussed above with respect to support assembly  12 . Sleeve  126  is a generally cylindrical and hollow sleeve, which comprises a tapered or narrowed end  126   a  and an inwardly curved end  126   b , similar to sleeve  26  discussed above. Likewise, tapered end  126   a  functions to force the cylindrical wall portions  20   a  of ball receiver  20  inwardly around ball member  16   b  of mount  16  in order to enhance gripping of ball  16   b  by receiver  20  and arm  14 , such that arm  114  may pivot relative to ball member  16   b , while ball member  16   b  is substantially precluded from being removed from socket  20  and sleeve  126 . Inwardly curved end  126   b  comprises an annular ridge or lip  126   c  which engages an outer shoulder  24   e  of second ball member  24  to substantially preclude longitudinally outward movement of second ball member  24  relative to sleeve  126 , similar to sleeve  26  and second ball member  24 , discussed above. 
   Sleeve  126  preferably includes one or more dimples or indentations  126   d , which are crimped inwardly to form bumps or ridges  126   e  along an inward surface  126   f  of sleeve  126 . Ridges  126   e  are positioned immediately longitudinally inwardly from an innermost portion  24   g  of cylindrical guide walls  24   e  of ball member  24 . As shown in  FIG. 5 , sleeve  126  may comprise multiple dimples  126   d  which are spaced circumferentially around sleeve  126 . However, a single circumferential groove or indentation may extend around sleeve  126  and engage innermost surface  24   g  of ball member  24  along its entire circumference, without affecting the scope of the present invention. As discussed above with respect to sleeve  26 , sleeve  126  preferably comprises a metal tubing, such as aluminum tubing, and may be powder coated to color match sleeve  126  with mount  16  and ball member  24  and/or the interior rearview mirror and/or the vehicle interior. However, other materials may be implemented, similar to sleeve  26 . The dimples may be die cast in sleeve  126  or may be crimped or otherwise formed therein. The lip  126   c  and ridges  126   e  function to rigidly secure or retain ball member  24  within sleeve  26 , thereby substantially precluding movement or vibration of ball  24  relative to sleeve  126  in either longitudinal direction. By reducing the possibility of relative movement between ball  24  and sleeve  126 , overall vibration of arm  114  and support assembly  112  is reduced. 
   Referring now to  FIGS. 6 and 7 , an alternate embodiment  212  of the mirror support assembly of the present invention is shown which comprises a mounting member  16  and an arm  214 . Mounting member  16  is substantially identical to the mount  16  discussed above with respect to support assembly  12  such that a detailed description will not be repeated herein. Arm  214  comprises an outer sleeve  26  which at least partially encases a ball receiving socket  220  and a base portion  224   b  of a second ball member  224 . Sleeve  26  is also substantially similar to sleeve  26  discussed above with respect to support assembly  12 . Second ball member  224  is likewise similar to ball member  24  and comprises a partial spherical member  224   a , a base region  224   b  and a neck region  224   c  extending between base region  224   b  and spherical portion  224   a . Spherical portion  224   a  may be approximately the same size as ball  16   b  on mount  16  or may have a greater diameter than ball  16   b , as discussed above with respect to ball  24   b  and ball  16   b  of support assembly  12 . 
   Ball member  224  may be cored or hollowed from either end to reduce the weight of the assembly, similar to ball  24  discussed above. Preferably, ball member  224  is cored from an outer or rearward end, as shown in  FIG. 6 , such that base portion  224   b  defines a continuous, substantially planar surface  224   f  at its forward end. Base portion  224   b  comprises a cylindrical side wall or annular guide  224   e  which extends longitudinally inwardly along an inner surface  26   f  of sleeve  26 . A substantially flat base surface  224   f  is formed along an inner surface of base portion  224   b  and is substantially encircled by cylindrical side walls  224   e . As discussed above with respect to ball member  24  and sleeve  26  of support assembly  12 , base portion  224   b  is formed to engage an annular ring  26   c  formed by inwardly curved portions  26   b  of sleeve  26 , thereby substantially precluding longitudinal movement of ball  224  outwardly with respect to sleeve  26 . Outer shoulders  224   d  of base portion  224   b  may be welded to sleeve  26 , such as by a rough texture in die cast using a spin weld or lathe type process, or may be otherwise secured to inwardly turned portions  26   b  of sleeve  26 . 
   Ball receiving member  220  comprises a ball receiving portion  220   b  and a biasing member portion  222 . Ball receiving portion  220   b  comprises cylindrical side walls  220   c , which may further comprise notches  220   g  at an outer end  220   h  thereof, and a base portion  220   a , which further defines a partially spherical surface  220   d  within cylindrical walls  220   c . An annular groove or channel  220   j  is formed around an outer edge of partially spherical surface  220   d  and immediately radially inwardly of cylindrical side walls  220   c , to facilitate inwardly bending of cylindrical walls  220   c  as the walls  220   c  engage tapered end  26   a  of sleeve  26 , similar to that discussed above with respect to support assembly  12 . 
   Biasing member  222  is preferably unitarily formed with ball receiving portion  220   b  of ball receiver  220  and extends longitudinally from base portion  220   a  such that a forward end  222   a  of biasing member  222  is integrally formed with base portion  220   a  of ball receiver  220 . Preferably, biasing member  222  is generally cylindrical and comprises an outer cylindrical wall  222   c  and a substantially flat or planar end surface  222   b  at an end of biasing member  222  opposite or rearwardly from base end  222   a . Preferably, ball receiver  220 , and thus biasing member  222  comprise an elastomer material which preferably has a spring rate of approximately 50 N/mm to 120 N/mm. 
   As assembled, ball receiver  220  is substantially encased by sleeve  26 , as shown in  FIG. 6 . Biasing member  222  has a longitudinal length such that planar surface  222   b  engages flat planar surface  224   f  of ball member  224  within guide walls  224   e . As assembled, biasing member  222  of ball receiver  220  is compressed such that biasing member  222  exerts a longitudinal force against base portion  220   a . Tapered ends  26   a  of sleeve  26  prevent further longitudinally outward movement of ball receiver  220 , since outer ends  220   h  of cylindrical side walls  220   c  become wedged between spherical ball member  16   b  and tapered end  26   a  of sleeve  26 . Annular guide  224   e  engages outer cylindrical surface  222   c  of biasing member  222  and functions to properly align and retain biasing member  222 , such that planar surface  222   b  of biasing member  222  remains substantially centered on base surface  224   f  of ball member  224 . 
   Referring now to  FIG. 8 , an interior rearview mirror  310  comprises a mounting arm  314  which extends from a back surface  310   a  of interior rearview mirror  310  in a direction generally forwardly with respect to the vehicle. Mounting arm  314  comprises a substantially cylindrical sleeve portion  326  extending from back surface  310   a  of interior rearview mirror  310 . Sleeve portion  326  is preferably fixedly secured to back  310   a  of interior rearview mirror  310  and may be unitarily formed with the mirror housing or casing. Sleeve portion  326  comprises an inwardly tapered or narrowed end  326   a  at an outer end opposite interior rearview mirror  310 . A ball receiving socket  320  is positioned within sleeve  326  and is substantially similar to ball receiver  20 , discussed above with respect to support assembly  12 . A partial spherical surface  320   b  and a cylindrical side wall  320   c  receive a ball member  16   b  of a mount  16 , which is substantially similar to mount  16  discussed above and is mounted to an interior surface  18   a  of windshield  18  in a known manner. A circumferential notch or channel  320   j  is formed between spherical surface  320   d  and walls  320   c  to facilitate radially inward flexing of walls  320   c  relative to partial spherical surface  320   d . Tapered end  326   a  of sleeve  326  functions to force an outer end  320   h  of cylindrical wall  320   c  inward around ball member  16   b , such that ball member  16   b  is pivotally secured within ball receiver  320  and sleeve  326 . Mirror assembly  310  is thus pivotally mounted to mount  16  via a single pivot joint. 
   Ball receiver  320  further comprises a flat or planar surface  320   e  on a base portion  320   a  and generally opposite partial spherical surface  320   d . A cylindrical, annular wall or guide portion  320   f  extends longitudinally inwardly toward interior rearview mirror  310  around a circumferential outer edge of planar surface  320   e . Mirror assembly  310  further comprises a cylindrical cavity or recess  310   b  which extends inwardly into interior rearview mirror  310  or generally rearwardly with respect to the vehicle. Cylindrical cavity  310   b  is defined by a cylindrical side wall  310   c  and an inner, substantially flat or planar end surface  310   d  within interior rearview mirror  310 . Cylindrical cavity  310   b  is generally centered with respect to sleeve  326 , such that cylindrical cavity  310   b  is generally aligned with annular guide portions  320   f  of ball receiver  320 . 
   A biasing member  322 , such as a coiled spring or the like, is positionable between planar surface  320   e  of ball receiver  320  and planar surface  310   d  of interior rearview mirror  310 . Biasing member  322  is guided and aligned between ball receiver  320  and interior rearview mirror  310  via the cylindrical side walls  310   c  of cavity  310   b  and guide walls  320   f  of ball receiver  320 . As discussed above with respect to biasing member  22 , biasing member  322  exerts a force on ball receiver  320  to press ball receiver  320  longitudinally along sleeve  326  such that cylindrical walls  320   c  of ball receiver  320  are pressed radially inwardly around spherical member  16   b  of mount  16 , as ball receiver  320  is moved toward and engages tapered end  326   a  of sleeve  326 , thereby facilitating pivotal engagement of connecting arm  314  on mount  16 , while substantially precluding removal of ball  16   b  from sleeve  326 . Although shown as a coil spring, biasing member may be any other known means for exerting a biasing force on socket  320 , and may be integrally formed therewith, similar to biasing member  222  and socket  220 , discussed above, without affecting the scope of the present invention. End  326   a  may be formed into the tapered or narrowed end after insertion of biasing member  322 , ball receiving socket  320 , and ball member  16   b  into cavity or recess  310   b.    
   Therefore, the present invention provides an interior rearview mirror support assembly which may be pivotally attached to a ball mount at a windshield or headliner or console of the vehicle. The support assembly may provide one or more pivotable ball and socket joints which facilitate pivotal movement of an accessory, such as an interior rearview mirror, relative to the substantially fixed ball mount on the window or headliner of the vehicle. A biasing member is positioned within a portion of the mounting assembly to maintain a tight grip on the ball member of the mount, while allowing rotational movement between the ball mount and a ball receiver within the support assembly. The biasing member is maintained in alignment with the ball receiver via at least one annular, cylindrical guide wall extending longitudinally along a portion of the support assembly. The guide wall substantially precludes lateral movement of the biasing member to maintain the biasing member in a proper orientation with respect to the ball receiver and support assembly, such that the force exerted by the biasing member on the ball receiver remains in substantially the same direction and is substantially constant to provide a substantially constant gripping force of the ball mount by the ball receiver. The present invention further provides reduced vibration in the interior rearview mirror due to the rigid connection of the mirror ball member with the arm or sleeve and the substantially uniform engagement of the ball mount via the aligned biasing member and the cylindrical walls of the ball receiver. 
   Referring now to  FIGS. 9-11 , an alternate embodiment  400  is disclosed which comprises a mount  416  and a mounting arm  414 , which pivotally connects to the mount  416  at one end and to an interior rearview mirror at an opposite end. The interior rearview mirror may comprise one or more electronic components, such that a mirror wiring harness or the like (not shown) may be routed to the mirror to provide power and/or control of the electronic accessories via a vehicle wiring harness at the headliner of the vehicle. Mount  416  is preferably a breakaway mount, such as disclosed in commonly assigned U.S. Pat. No. 5,820,097, issued to Spooner, the disclosure of which is hereby incorporated herein by reference, but may be other button or channel mounts, without affecting the scope of the present invention. 
   Mount  416  preferably comprises a breakaway resilient retainer  416   a , which is adapted to engage a button (not shown) secured to the windshield. Retainer  416   a  comprises a plurality of mounting flanges  416   b  for removably securing the retainer to the button, and a ball receiving socket  416   c  for pivotally receiving a ball member therein, as discussed below. Mount  416  further comprises a casing  416   d  which is mountable on retainer  416   a  to cover the retainer and provide a finished appearance to the mount  416 . Preferably the cover  416   d  comprises a molded polymeric, plastic material, which may further include a channel  416   e  for a mirror wiring (not shown) to be routed and secured therethrough. 
   Mounting arm  414  is preferably a double ball arm, which comprises a central shaft portion  414   a  and opposite ball members  414   b  and  414   c . Ball members  414   b  and  414   c  are attached to respective neck portions  414   d  and  414   e  at opposite ends of shaft portion  414   a . A first ball member  414   b  is pivotally connectable to ball receiving socket  416   c  of mount  416 , while the second ball member  414   c  is pivotally secured within a ball receiving socket of the interior rearview mirror (not shown). A socket such as that shown in embodiment  310  would be suitable. Mounting arm  414  further comprises a cover member  415 , which substantially encases shaft portion  414   a  of arm  414 . Preferably, as shown in  FIG. 10 , cover member  415  is slotted along its entire length to facilitate expansion of the slot or opening  415   e  for insertion of shaft  414   a  therewithin. Cover member  415  is biased to return to its closed position to secure shaft  414   a  within cover member  415 . Cover member  415  preferably comprises a plastic material, such as polypropylene, EPDM, or the like, and is preferably moldable in a desired color to match the interior rearview mirror or interior color scheme or trim of the vehicle. As shown in  FIG. 10 , cover member  415  has a generally circular cross-section, which defines a generally circular passageway  415   a  extending therealong. A channel or groove  415   b  is also provided along passageway  415   a  to provide a passageway for the mirror wiring harness between the wiring channel  416   e  of mount  416  and the interior rearview mirror. 
   It is further envisioned that cover member  415  may further comprise a recess  415   c  and a slotted cover plate  416   d  which covers or encloses recess  415   c . Recess  415   c  may contain scented inserts or the like, for providing an air freshener in the vehicle, which would not be visible to an occupant of the vehicle. Additionally, recess  415   c  may be positioned substantially adjacent to wiring groove or channel  415   b , such that the scented inserts may be of the type whereby performance is enhanced through heating, with the heat being provided by the resistance in the wiring when one or more of accessories associated with mounting arm  414  is in use. 
   Referring now to  FIG. 11 , an alternate embodiment of the invention comprises a mounting base  516 , a mounting arm  514  and an accessory such as an interior rearview mirror  510 . The interior rearview mirror may comprise one or more electronic accessories, such that a mirror wiring  511  is connectable between interior rearview mirror  510  and a vehicle wiring harness or wiring (not shown). Mount  516  is mountable to an interior surface of the windshield and comprises a mounting button or the like  516   a  and a ball receiving mounting retainer  516   b , which is mountable to button  516   a  to secure mount  516  to the windshield or the like. Retainer  516   b  preferably comprises a ball receiving socket  516   c  for receiving a ball member, as discussed below. Preferably, a wiring passageway  516   d  is provided in retainer  516   b  to facilitate routing of the mirror wiring through the retainer and into ball receiving socket  516   c . Preferably, retainer  516   b  further comprises a cover to provide a finished appearance to the mount  516 . The cover preferably comprises a plastic material, which may be molded in color to match the color of the trim or accessories of the vehicle. 
   Mounting arm  514  is preferably a double ball mounting arm, which comprises a central shaft portion  514   a  and a ball member  514   b  and  514   c  positioned at opposite ends of the shaft portion  514   a . A passageway  514   d  is provided through mounting arm  514 , preferably through a center portion of ball members  514   b  and  514   c  and shaft portion  514   a , for receiving and routing the mirror wiring  511  from passageway  516   d  of mount  516  to a corresponding passageway  510   a  of interior rearview mirror  510 . Mirror assembly  510  comprises a ball receiving socket  510   b  for receiving ball member  514   c  of arm  514  and a wiring passageway  510   b  for receiving the mirror wiring from passageway  514   d  and arm  514 . Ball receiving socket  516   c  of mount  516  likewise receives ball member  514   b  of arm  514 , such that the wiring which is routed through passageway  516   d  in mount  516  is further routed through passageway  514   d  of arm  514  and into passageway  510   b  of interior rearview mirror  510 . Preferably, passageway  514   d  is flared outwardly at either end to facilitate movement of the mirror wiring as one or both ball members are pivoted within their respective sockets, thereby substantially reducing the possibility of cutting or damaging the wiring as the mirror and/or arm  514  are pivoted relative to the mount  516 . 
   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.

Technology Classification (CPC): 1