Patent Abstract:
A rearview mirror with lighting assembly for use in a vehicle, has a molded case adapted to support lights for illuminating portions of the vehicle interior, to support electrical switches, wiring, and electrical connectors, to support optical lenses for directing light, and to support a mirror element. The case includes ventilation around the lenses, past the lights, and out of the case for dissipating heat from the lighting. The electrical switches and connectors are mounted into the case. A preferred light arrangement provides illumination of areas below and outwardly of the case ends with targeted lighting areas in the lap areas of persons seated in the front seats of the vehicle, without allowing light to be directed toward the vehicle windshield or instrument panel to cause glare. A resilient sealing material is adhered to the back of the lens element for sealing with the case to prevent or minimize the emission of uncontrolled, stray light from the case. The sealing material is preferably adhered to the mirror element by an adhesive carrier layer which preferably also provides an antiscatter function for the mirror element in the event of breakage.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a continuation of application Ser. No. 09/133,343, filed Aug. 13, 1998, by Howard W. Fant Jr., Troy I. Vanderhoof, Craig M. Miller, and Barry W. Hutzel, entitled REARVIEW MIRROR WITH LIGHTING ASSEMBLY, the disclosure of which is hereby incorporated by reference herein, which is a continuation of Ser. No. 08/332,429, filed Oct. 31, 1994, now issued as U.S. Pat. No. 5,813,745, which is a continuation of Ser. No. 07/945,238, filed Sep. 15, 1992, now abandoned, which is a division of Ser. No. 07/760,077, filed Sep. 13, 1991, now issued as U.S. Pat. No. 5,178,448. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to rearview mirror assemblies for vehicles and, more particularly, to a case assembly for a rearview mirror which provides lighting for illuminating selected portions of a vehicle interior and which includes controls for providing such illumination, mounted on the front of the assembly. 
     Various types of rearview mirror assemblies which provide lighting have been used in the past. One such structure includes a housing secured to the back of a rearview mirror case and having a pair of light assemblies mounted on the housing for insertion into the case, through openings in the case back, so that light is directed downward from the spaced lights. The lighting provided by the structure was appropriate for low level interior courtesy lighting for the front passenger area of a vehicle. However, the housing of this prior mirror assembly wrapped around the case back to the bottom of the case and was, in part, visible by the driver of the vehicle. Moreover, adaptability of this assembly to sophisticated vehicle interior designs was limited. 
     Subsequent rearview mirror assemblies including lighting as an integral part of the assembly have been developed. Such development commonly involved inserting a miniature lamp assembly into a standard mirror case which had been minimally modified to increase interior volume as required for the lamp assembly. Many such assemblies have developed overheating problems and are commonly expensive devices with fragile control wiring. A common practice for providing electrical current to such prior illuminating mirror assemblies commonly involved a wire raceway extending out of the mirror case for connection with the vehicle electrical power circuit. These wire raceways which extend from the mirror case are subject to twisting and tension, each of which tend to wear and break the raceway and transmit stress to wiring inside the case. Further, the wiring inside the mirror case has commonly employed slip fit connectors at each electrical component. Such connectors are often subject to disconnection because of vibration and other causes, inherent in a vehicle environment. 
     Such prior assemblies are also commonly susceptible to the development of glare in the mirror element, on the vehicle windshield, and on the vehicle instrument panel, because of the emission of stray or uncontrolled light. As may be well appreciated, such glare creates a safety hazard. In a passenger compartment of a vehicle, it is desirable to minimize, if not eliminate, glare reflecting from the windshield or the instrument panel. Thus, a primary consideration in the design of an illuminating mirror assembly is the containment and direction of light generally away from the windshield and dash areas and toward the laps of the passengers, where the lighting will be most useful. 
     The present invention was conceived as a solution for and an improvement over the above and other design limitations of prior known lighted rearview mirror structures which provide illumination. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention provides a case assembly for vehicular rearview mirrors adapted to define a compartment on or within the case and, which, in a preferred embodiment is effectively sealed against the back of the mirror element. Preferably, the sealing means also provides an antiscatter function for the mirror element in the event of breakage. 
     A rearview mirror assembly according to one form of the present invention includes a case having a back wall and a perimeter side wall defining an interior space within the case. Walls extending within the case from the back wall define a compartment within the case. The compartment is connected with the outside of the case through an opening located in a bottom portion of the side wall. A mirror element is supported and retained by the case, opposite from the back wall. A sealant is provided between the compartment walls and the back of the mirror element to seal the compartment and prevent escape of uncontrolled or stray light from the compartment. 
     In one aspect of the invention, a reflector with a progressive or variable radius of curvature is provided in the compartment for selectively directing light out of the compartment. In another aspect of the invention, the case is adapted to receive electrical components, specifically, controls, light bulb holders and a power plug, for powering a lamp assembly positioned in the compartment. The electrical components are mounted to the housing for improved durability and reliability of the control wiring system. Specifically, a power plug connects the mirror assembly with the vehicle electrical system and the power plug is mounted in the back wall of the case of the mirror assembly. A switch is provided in the mirror assembly and also mounted to the case for controlling the electrical current to and thus illumination of the lamp assembly. Finally, the electrical components, i.e. the power plug, the switch, and the lamp assembly, are directly connected, one with another, by wiring, without intermediate connectors. 
     In yet another aspect of the invention, a lens is mounted in the side wall opening to refract and reflect light projected from the lamp assembly, away from the windshield and instrument panel of a vehicle in which the assembly is mounted. In a further aspect of the invention, the compartment on or within the case is ventilated to dissipate heat from the compartment. The lens and opening define a ventilation passage between the lens and the case for the flow of air from outside the case, around the lens, and into the compartment. A ventilation hole or passage in the back of the mirror case and communicating with the compartment is also provided. A ventilation conduit, positioned generally opposite the compartment from the lens, may also be provided and extends from the compartment to outside the case. A light baffle or maze is formed by the conduit so that light may not escape from the compartment through the ventilation conduit. 
     The rearview mirror assembly of the present invention provides an improvement over the prior art with a simplified and more durable lighting assembly. Many of the electrical interconnections which are used in previous control wiring systems have been eliminated in the present mirror assembly to enhance durability. Improved sealing of stray or uncontrolled lighting is also accomplished in the present assembly. Further, enhanced control of the distribution pattern of light projected from the assembly is provided by unique reflector usage and design and by unique lens design. Also, improved ventilation of the lighting assembly is also provided. All of this is accomplished in a lighter weight and less expensive assembly because of the simplification of the present assembly over the prior art. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a lower front perspective view of a mirror assembly according to the present invention; 
     FIG. 2 is an upper rear perspective view of the mirror assembly of FIG. 1; 
     FIG. 3 is a bottom plan view of the mirror assembly of FIG. 1; 
     FIG. 4 is a top plan view of the mirror assembly of FIG. 1; 
     FIG. 5 is a right end elevational view of the mirror assembly of FIG. 1, the opposing end being substantially similar; 
     FIG. 6 is an exploded perspective view of the mirror assembly of FIG. 1; 
     FIG. 7 is a sectional view along plane VII—VII of FIG. 5; 
     FIG. 8 is a front elevation of the mirror housing of FIG. 7 with the components removed to show only the housing; 
     FIG. 9 is a cross-sectional view along plane IX—IX of FIG. 7; 
     FIG. 10 is a fragmentary plan view along plane X—X of FIG. 9; 
     FIG. 11 is an exploded sectional view along plane XI—XI of FIG. 8; 
     FIG. 12 is a front elevational view of the driver&#39;s side reflector; 
     FIG. 13 is a cross-sectional view along plane XIII—XIII of FIG. 12; 
     FIG. 14 is a front elevational view of the passenger side reflector; 
     FIG. 15 is a cross-sectional view along plane XV—XV of FIG. 14; 
     FIG. 16 is an end elevational view of the driver&#39;s side lens; 
     FIG. 17 is an end elevational view of the passenger&#39;s side lens; 
     FIG. 18 is a schematic diagram of the view of FIG. 9, showing a light ray trace from the driver&#39;s side light bulb filament; 
     FIG. 19 is the view of FIG. 18 with the filament deviated from the design location; 
     FIG. 20 is a front elevational view of the assembly of FIG. 1 showing a light ray trace from the assembly; 
     FIG. 21 is a schematic diagram of the wiring for the assembly of FIG. 1; 
     FIG. 22 is a top plan view of the driver&#39;s lens; 
     FIG. 23 is a bottom plan view of the driver&#39;s lens; 
     FIG. 24 is a top plan view of the passenger&#39;s lens; 
     FIG. 25 is a bottom plan view of the passenger&#39;s lens; 
     FIG. 26 is the view of FIG. 16 exploded into three fragments and showing specific dimensions; 
     FIG. 27 is an enlarged view of detail XXVII of FIG. 26, showing specific dimensions; 
     FIG. 28 is the view of FIG. 17, showing specific dimensions; 
     FIG. 29 is an enlarged cross-sectional view along plane XXIX—XXIX of FIG. 25, showing specific dimensions; 
     FIG. 30 is a fragmentary cross-sectional view along plane XXX—XXX of FIG. 23, showing specific dimensions; and 
     FIG. 31 is a fragmentary cross-sectional view along plane XXXI—XXXI of FIG. 23, showing specific dimensions. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the drawings in greater detail, a mirror assembly  30  according to the present invention is generally shown in FIGS. 1-31. Assembly  30  has a case  32  with a back wall  34  and a perimeter side wall  36 , defining an interior space within case  32  (FIGS.  6 - 9 ). Case  32  may be molded of a variety of known, suitable materials, but is preferably molded of a fiber reinforced plastic and most preferably of a 13% glass fiber reinforced nylon plastic. A mounting aperture  38  in back wall  34  is generally centered along the length of case  32  and is preferably located near an upper portion  40  of sidewall  36  (FIG.  2 ). A mounting arm  42  is connected with case  32  by an actuator  44 , described below. Mounting arm  42  extends from case  32  to a fixed member of a vehicle for mounting assembly  30  in the vehicle. 
     Assembly  30  is preferably a day/night rearview mirror having a high reflectivity day position and a reduced reflectivity night position, wherein reflection of undesired and distracting glare from behind the vehicle is reduced or eliminated in the night position. Thus, mounting arm  42  is preferably connected with case  32  through a day/night actuator  44  (FIGS. 2,  5  and  6 ). Actuator  44  may comprise a toggle member  46  and a pivot lever  48  as are known in the art. Actuator  44  is preferably of the type disclosed in copending and commonly assigned U.S. Pat. No. 5,327,288, entitled REDUCED VIBRATION DAY/NIGHT REARVIEW MIRROR ASSEMBLY, invented by Wellington et al. and filed on even date herewith, the disclosure of which is hereby incorporated by reference. 
     A prismatic mirror element  50  is mounted to the front of case  32 , opposite back wall  34 , by a circumscribing bezel  52  (FIGS. 1,  3 - 6 ,  9  and  11 ). Mirror element  50  is preferably a transparent, prismatic element of glass or plastic or other suitable optical material and has nonparallel front  54  and back  56  surfaces. Back surface  56  has a thin layer of reflective material such as metallic silver or chrome or the like as is commonly known and is most preferably provided with a protective, antiscatter layer for safety in the event the mirror element is broken. 
     As mentioned above, bezel  52  circumscribes mirror element  50  and further, has a circumferential lip  58  which extends over front surface  54  of mirror element  50 , near the perimeter edge of the mirror element, to capture and hold mirror element  50  against case  32  (FIGS.  9  and  11 ). Bezel  52  is irremovably connected with case  32  by a series of perimeter latch fingers  60  which extend toward case  32  from bezel  52  and have a projecting, wedge shaped hook  62  on the side of each finger  60  for engagement with corresponding latch loops  64 , provided around the perimeter of case  32 . Each latch loop  64  is a generally U-shaped member having a bight portion  66  for engagement with one of hooks  62 . Fingers  60  are forced between perimeter side wall  36  and latch loops  64  to wedge each bight portion  66  away from side wall  36  until hook  62  passes bight portion  66 , which then returns to its previous position and captures the hook to prevent withdrawal. 
     Case  32  preferably seals against back surface  56  of mirror element  50 . Most preferably, a resilient foam layer  68 , such as commonly available polyester, number four, closed cell foam, generally covers and is adhered to back surface  56  by an adhesive carrier layer  70  (FIGS.  9  and  11 ). Carrier layer  70  is preferably a polyester film of about two mil thickness, coated with a synthetic rubber base PSA adhesive to adhere to back surface  56 . When adhered to back surface  56 , carrier layer  70  provides the antiscatter function discussed above, for mirror element  50 . 
     Walls  72 ,  74  extend generally forward from back wall  34  and define a driver&#39;s side closed lamp compartment  76  and a passenger&#39;s side closed lamp compartment  78  inside case  32  for housing illuminating lamp assemblies (FIGS.  7  and  8 ). Further, an opening  80  for the driver&#39;s side and an opening  82  for the passenger&#39;s side are provided in a bottom portion  84  of side wall  36  for transmitting light out of each compartment  76 ,  78  and case  32 . 
     Ventilation is provided for each compartment  76 ,  78  by ventilation holes  86 , located above compartment  76 , and ventilation holes  88 , located above compartment  78  (FIGS. 2,  4 ,  7  and  8 ). Ventilation holes  87 ,  89  (FIGS. 2,  8  and  9 ) extend through back wall  34  at a position spaced below ventilation holes  86 ,  88  respectively, in the lower area of each compartment  76 ,  78 . U shaped walls  91 ,  93  on back wall  34  extend around and below vent holes  87 ,  89  within each compartment such that each wall has a portion between vent hole  87  or  89  and opening  80  or  82  as well as portions extending upwardly on either side of the respective vent holes. Walls  72  and  74  extend to side wall upper portion  40 , defining ventilation conduits to connect holes  86  and  88  with compartments  76  and  78 , respectively. However, a straight path is not allowed out through holes  86  and  88  from compartments  76  and  78 . A light maze or baffle is formed between each of holes  86  and  88  and a main chamber of each compartment  76 ,  78  so that light may not escape through holes  86  and  88 , from the respective compartment  76 ,  78 , to cause potential glare (FIGS.  7 - 9 ). 
     On the driver&#39;s side, narrowed throat  94  is formed between holes  86  and a main portion of compartment  76 , along conduit  90 , by walls  72  (FIGS.  7  and  9 ). A baffle plate  96  extends forward from back wall  34 , between throat  94  and holes  86 . Baffle  96  is wider than throat  94  and extends laterally across holes  86  so that a direct light path does not exist out of compartment  76 , through holes  86 . Baffle  96  does not, however, extend to walls  72  to thus provide air flow from compartment  76 , through throat  94 , around either end of baffle  96 , and out vent  86 . 
     On the passenger&#39;s side, narrowed throat  98  is formed between holes  88  and a main portion of compartment  78 , along conduit  92 , by walls  74 , similar to the driver&#39;s side of assembly  30  (FIGS.  7  and  8 ). Unlike the driver&#39;s side, though, a baffle plate  100  extends forward from back wall  34 , between throat  98  and the main portion of compartment  78 . Further, baffle  100  does extend to wall  74  at one end of baffle  100 , maintaining an air passage at the opposing end of baffle  100 . In fact, baffle  100  extends from one side of throat  98 , defining a bent channel portion  102  of conduit  92  for the passage of air from compartment  78 , through channel  102 , and out holes  88  and for blocking the escape of light from compartment  78 . 
     A driver&#39;s lens  104  and a passenger&#39;s lens  106  are positioned in each opening  80  and  82 , respectively (FIGS. 1,  3 ,  7  and  8 ). As is best seen in FIGS. 1 and 9, each lens is recessed into the case bottom sufficiently to eliminate direct light into the eyes of the driver or passenger. This is accomplished by molding case with openings  80 , 82  recessed into the sidewall bottom. Each lens  104 ,  106  has a perimeter edge  108 , and each opening has a perimeter edge  112  (FIG.  10 ). The lens edge  108  is spaced from the opening edge  112  defining a ventilation passage into compartments  76  and  78  through openings  80  and  82 , around the lenses  104 ,  106 , respectively (FIGS.  7 - 9 ). Thus, air may enter the compartments  72 ,  76  through holes  87 ,  89  and around the lenses  104 ,  106  and vent off heat, through the light baffles and vent holes  86  and  88 . 
     Each lens  104 ,  106  is a transparent element of glass or plastic or other suitable optical material and is preferably molded of a clear polycarbonate plastic such as LEXAN, which is commonly available from the General Electric Corporation. Passenger&#39;s lens  106  has a series of generally parallel ridges  116  and grooves  118  extending across a top surface  120  to refract and reflect light from compartment  78  generally forward relative to mirror assembly  30  and away from the vehicle&#39;s windshield (FIGS. 17,  24 ,  25 , and  28 ). Generally, the surfaces of ridges  116  are polished smooth except for the surfaces of optical facets C (FIG. 28) which are made slightly dull to help diffuse light in these areas. A Fresnel lens pattern typically formed using rotary cutters, is provided at 90° to ridges  116  and  118  grooves on a bottom surface  122  of passenger&#39;s lens  106  to control lateral dispersal of light projected through the lens, principally minimizing the potential for any uncontrolled stray light to be projected toward the driver (FIG.  29 ). 
     Similar to passenger&#39;s lens  106 , driver&#39;s lens  104  also has a series of laterally extending, generally parallel ridges  124  and grooves  126  across a top surface  128  (FIGS. 16,  22 ,  23 ,  26 , and  27 ). However, direction and control of light projected from compartment  76 , away from the instrument panel of the vehicle, is somewhat more critical on the driver&#39;s side than on the passenger&#39;s side. Therefore, ridges  124  and grooves  126  include prominent, taller teeth  130  and  132  which refract or reflect and block light which would otherwise be projected to the instrument panel, causing glare (FIGS. 18,  19 , and  26 ). As with passenger&#39;s side lens  106 , lens  104  has parallel and planar surfaces on ridges  124  which face generally away from case back  34  while parallel and curved surfaces on the ridges face generally toward back wall  34 . The curved surfaces on taller teeth  130 ,  132  do face away from case back  34  however, while the planar surfaces on those teeth face toward the case back. Also, ridges  130 ,  132  project above their adjacent grooves by at least twice as far as the remaining ridges project above their grooves to insure all remaining light is directed forwardly as described below. Generally, the surfaces of all ridges  124  are polished smooth except for the surfaces of optical facets  3 A on tooth  130 , and of optical facets  7  and  8  (FIGS.  26  and  27 ). These surfaces are made slightly dull with sandpaper to help diffuse light in these areas. 
     A slightly different Fresnel lens pattern from that on lens  106  and also formed with rotary cutters is provided on a bottom surface  134  of driver&#39;s lens  104  to control lateral dispersal of light projected through the lens and to help direct light away from the instrument panel and into the passenger compartment (FIGS. 23,  30  and  31 ). Typically, Fresnel lens optic facets or elements in vehicular interior lighting fixtures on one lens surface are oriented at 90° to the optic facets, ridges and grooves on the opposite surface as in passenger side lens  106 . Hence, one side ( 120 ) is used for directing light away from the instrument panel while the opposite side ( 122 ) provides lateral or side to side direction and target control. In lens  104 , however, the Fresnel optic facets or elements are at an angle to the grooves and ridges  124 ,  126  on side  128  other than at 90° to help control and direct light away from the instrument panel as well as controlling the lateral light direction. Preferably, the Fresnel facets are oriented in a V-shaped pattern (FIG. 23) each at an angle of about 68° to ridges and grooves  124 ,  126  on top surface  128 . The V-shaped Fresnel pattern also helps to smoothly spread the light over the target area. 
     Each of a reflector  136 ,  138 , a light bulb  140 , and bulb holders  142 , are also located in compartment  76  and  78 , respectively (FIG.  7 ). Bulbs  140  are preferably a cartridge style bulb, having a metallic connector at each end and a four candle power rating. 
     Bulb holders  142  are held in case  32  by insertion into receptacles  144  formed in case  32  by upstanding posts and walls which project forward from back wall  34  and provide openings to dissipate heat, presenting an aperture  146  which corresponds to bulb holders  142  (FIGS.  7  and  8 ). Bulb holders  142  are stamped and formed from strips of springy and conductive metal to define a fastening tang  148  for insertion into receptacles  144  (FIG.  9 ). Projecting generally perpendicularly to fastening tang  148 , at one end, bulb holders  142  have a generally cylindrically shaped area  150  where a bulb  140  is positioned in use. Flared receiving flanges  151  for ease of insertion of bulb  140  into cylindrical area  150  are also provided. 
     The configuration of receptacles  144  and bulb holders  142  utilizes a forward to rearward direction relative to case  32  for inserting holders  142  into receptacles  144 , enhancing a manufacturer&#39;s assembly. Further, the direction of insertion and removal of bulb  140  from bulb holders  142  is perpendicular to the direction for inserting holders  142  into receptacles  144 , minimizing the potential for inadvertently removing holders  142  from receptacles  144  during subsequent removal and replacement of a damaged bulb. 
     Each reflector  136 ,  138  is preferably formed as a generally U-shaped member from 0.020 inch (0.50 mm) thick, bright dipped, anodized, quarter hard aluminum  5657  alloy (FIGS.  12 - 15 ). Reflectors  136  and  138  have mounting flanges  152 ,  154  and heat shields  156 ,  158  extending in the same general direction from opposite edges of a bight portion  160 ,  162 , respectively. The inside surfaces of reflectors  136 ,  138  preferably provide at least 80% reflectivity. A pair of mounting apertures  164  are provided in each mounting flange  152 ,  154  for snap or force fit over corresponding mounting posts  166 , which project forward from back wall  34  of case  32  (FIGS.  7  and  8 ). Ridges  168  are formed along each heat shield  156 ,  158 , generally parallel to bight portions  160  and  162 , to minimize the area of contact between the heat shields  156 ,  158  and back surface  54  of mirror element  50  and any foam layer  68  thereon and, thus, the amount of heat transferred to mirror element  50  and layer  68  (FIGS.  9  and  12 - 15 ). Further, ventilation slots  170  are positioned in mounting flanges  152 ,  154  for enhanced air convection around the reflectors  136 ,  138 , respectively. 
     Passenger&#39;s reflector  138 , is generally angled relative to case  32  to direct light generally away from the driver and to the lap area of the passenger (FIGS. 14,  15  and  20 ). Bight portion  162  of reflector  138  is generally spherically cup shaped, forming a reflective surface  172  to enhance the focus and direction of light projected from surface  172 , away from the driver&#39;s side of the vehicle. 
     Driver&#39;s reflector  136  is generally squarely oriented in case  32  to project light generally directly downward (FIGS. 12,  13  and  20 ). Bight portion  160  of reflector  136  is also generally spherically cup shaped, is curved along two axes, and has a progressively lengthening radius of curvature, moving from a front edge  174  of bight portion  160  to a back edge  176  of bight portion  160 , near back wall  34 , forming a reflective surface  178  (FIG.  18 ). The longer radius of curvature near back edge  176  directs light reflected from a filament  180  of bulb  140  farther forward, relative to mirror assembly  30 , than the adjoining shorter radius portion of the reflector, toward front edge  174  (FIGS. 12,  13 ,  18  and  19 ). Also, the cup shape helps direct light toward the target lap area of the driver. While surface  178  may be a continuous, smoothly curved surface of progressively changing radius of curvature, a significant cost savings may be had by approximating the continuous, smoothly curved surface with a composite surface comprising adjoining, constant radius portions with the radii changing in a stepwise manner. Thus, surface  178  is preferably a composite surface, having a constant radius portion  178   a  and an adjoining constant radius portion  178   b  with a longer radius than portion  178   a.    
     A shown in FIGS. 7 and 9, each of reflectors  136 ,  138  is mounted within case  32  with mounting flanges  152 ,  154  spaced inwardly from back wall  34  and extending toward the top wall of case  32 , while bight portions  160 ,  162  curve forwardly toward mirror element  50 . Thus, each reflector  136 ,  138  includes portions of mounting flanges  152 ,  154  or bight portions  160 ,  162  which are located closer to at least one of the top wall or back wall of case  32  than light bulbs  140  when the bulbs are positioned within bulb holders  142 . 
     As shown in FIGS. 18 and 19 of a cross-sectional view of driver&#39;s reflector  136 , driver&#39;s lens  104 , and a light bulb  140 , having a filament  179 , and indicating light ray traces from filament  179 , it is seen how each of the driver&#39;s reflector  136  and the driver&#39;s lens  104  independently and jointly direct the light emitted from filament  179 , generally toward an area beneath and forward of mirror assembly  30 . Uncontrolled, undesired, stray light which might otherwise project rearward of assembly  30  is reflected or blocked by higher teeth  130  and  132  of lens  104 . This system of light control with reflector  136  and lens  104  is effective whether the bulb filament  179  is in its design position  179  as shown in FIG. 18 or is in a least desirably deviated position, upward and forward from a design position at position  179   a,  as shown in FIG.  19 . Such deviation of filament  179  may commonly be experienced since specific placement of filament  179  within bulb  140  is not typically a concern of bulb manufacturers. 
     Electrical current for energizing bulbs  140  is provided through a wiring harness which is schematically shown in FIG. 21. A power plug  180  is mounted in case  32 , through an aperture  182  in back wall  34  (FIGS. 2,  7 ,  8  and  11 ). Power plug  180  is a three conductor plug which snap fits into aperture  182  by resilient spring clips  184  which project at an angle with respect to power plug  180  and have a terminal end or shoulder  186  (FIG. 11) clips  184  fold or compress when power plug  180  is inserted into aperture  182 , clips  184  pass through the aperture, and snap back to their initial, spread position behind a lip  188 , adjacent aperture  182 . Shoulders  186  abut lip  188  to lock plug  180  in place in back wall  34 . Power plug  180  may then be connected with the vehicle electrical system, typically a twelve volt, negative ground system, by a cooperating, power supply plug (not shown) which is adapted to mate with plug  180 . By fixing power plug  180  to case  32 , any tendency to physically stress and damage the internal wiring harness of mirror assembly  30  is minimized, if not eliminated. In contrast, prior mirror assemblies requiring wire connections to the interior of the assembly typically have a cable penetrating the case, whereby tension applied to the cable will stress the internal wiring of the mirror assembly, causing damage to the internal electrical system. 
     Referring specifically to FIG. 21, showing a schematic representation of the wiring harness for mirror assembly  30 , power is supplied to mirror assembly  30  from the vehicle electrical system, through a power supply plug (not shown) which mates with power plug  180  and connects with a first terminal  190  in power plug  180 , providing a source of current at terminal  190 . Terminal  190  is in turn connected with a first bulb holder  142   a,    142   d  of each of a driver&#39;s light bulb  140   a  and a passenger&#39;s light bulb  140   b,  respectively. 
     A second terminal  192  in power plug  180  provides a connection directly with the vehicle system ground. Terminal  192  is connected with a first contact  194  on a switch  196  for controlling the driver&#39;s lamp and is also connected with a first contact  198  on a switch  200  for controlling the passenger&#39;s lamp. Each switch  196 ,  200  is a single pole, double throw switch to provide connection between a center or common contact  202 ,  204  and a first contact  194 ,  198  or, alternatively, between the center contact  202 ,  204  and a third contact  206 ,  208 , respectively, as is well known in the art. As shown in FIGS. 1,  3 ,  4 ,  6 ,  7  and  11 , switches  196 ,  200  are located in the front face of bezel  52  to be accessible visibly and physically to the driver and/or passenger. Such location also indicates to the driver and/or passenger that additional features, namely lights, are included in the mirror assembly. 
     Common contact  202  of switch  196  is connected with a second bulb holder  142   b  so that when switch  196  is closed between the first  194  and common  202  contacts, a circuit is completed and bulb  140   a  is illuminated. Similarly, common contact  204  of switch  200  is connected with a second bulb holder  142   c  so that when switch  200  is closed between first contact  198  and common contact  204 , a circuit is closed and bulb  140   b  is illuminated. 
     A third terminal  210  in power plug  180  provides connection with the vehicle system ground through a vehicle door switch system (not shown) as is commonly known for providing a connection with the vehicle system ground when a vehicle door switch is closed by opening a corresponding vehicle door. Third terminal  210  is connected with the third contact  206 ,  208  in each of the driver&#39;s and passenger&#39;s switches  196 ,  200 , respectively. When each switch  196 ,  200  is not closed between its common contact  202 ,  204  and its first contact  194 ,  198 , each switch is closed between the common contact  202 ,  204  and the third contact  206 ,  208 , respectively. Thus, each switch  196 ,  200  will operate to either close directly to ground and allow electrical current to pass through and illuminate the light bulbs  140   a,    140   b,  or each switch  196 ,  200  will close a circuit to the door switch circuit so that the light bulbs  140   a,    140   b  are illuminated when a corresponding vehicle door is opened. 
     Each of the electrical components, i.e. power plug  180 , switches  196 ,  200 , and bulb holders  140 , are directly wired with each other as described above, without intermediate or inline connectors. Such intermediate connectors are well known in prior mirror assemblies. The elimination of such intermediate connectors in the present mirror assembly  30  eliminates a major potential for open connectors and provides a significantly more durable and reliable wiring system for the mirror assembly. 
     Each switch  196 ,  200  is also snap fit into case  32  (FIGS. 7,  8  and  11 ). Switch receptacles  216  and  218  are provided in case  32  and positioned one on either side of actuator  44 , for receiving and holding each switch  196 ,  200 , respectively (FIG.  8 ). Pairs of flanges  220  define channels  222  into which mounting tabs  224  on each switch  196 ,  200  are inserted (FIGS.  8  and  11 ). Further, a wedge portion  226  is provided on a bottom side of each switch  196 ,  200  and cooperates with a wedge shaped hook  228 , projecting from side wall bottom portion  84 . As either switch  196 ,  200  is inserted into its receptacle  216 ,  218 , respectively, wedge  226  ramps over hook  228 , temporarily displacing hook  228  until wedge  226  has passed hook  228  and hook  228  returns to its normal position to capture wedge  226  and lock the switch  196 ,  200  in place in case  32 . 
     As will now be apparent, the assembly of case  32 , lenses  104 ,  106 , bulbs  140 , reflectors  136 ,  138 , the wire harness, bulb holders  142 , switches  196 ,  200 , and power plug  180  are all integrated together thereby eliminating the necessity of separate light modules and reducing the overall number of parts in the mirror. 
     The above description is considered that of the preferred embodiment only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment shown in the drawings and described above is merely for illustrative purposes and is not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law.

Technology Classification (CPC): 1