Abstract:
An electrified rearview mirror includes a housing supporting a rearview mirror subassembly, and a bezel attached to the housing. The bezel includes a section of material defining a plurality of three-sided button openings on a face of the bezel, with the openings extending onto a bottom wall of the housing. A push-button is pivotally supported in each opening, with the hinge axis of the push-buttons being at a low position on the respective buttons so that the buttons are not accidentally depressed when the mirror housing is grasped by a vehicle driver to adjust an angle of the mirror. The bezel and buttons include pairs of tabs and mating slots that form a quick-attach bottom pivot, and further include stops and hooks at their top that form stroke-limiting mechanisms for controlling button movement. The buttons can be operably snapped into position on the bezel with minimal assembly time. A finger rail depression extends along the bottom wall of the housing parallel the buttons to facilitate a driver sliding his/her fingers along the mirror to a desired position for selecting a particular button to depress. Further, the buttons include feel locators that help the driver identify particular buttons without looking at the buttons.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to electrified mirrors with actuation buttons for activating circuits and functions in a vehicle. 
     An increasing number of vehicle electronics are being packaged in interior rearview mirrors. The reasons are many and varied, but are closely related to the fact that the interior rearview mirror location, which is relatively high and near the vehicle front windshield, provides good physical and visual accessibility, low electromagnetic noise and in turn, good undistorted signal-receiving capability, and proximity to the vehicle exterior (which facilitates multiple functions such as compass/direction sensing, global position sensing, temperature sensing, daylight sensing, sensing of glaring light such as bright headlamps, keyless entry, passenger airbag on/off control, telecommunication functions, and the like). However, the amount of features and options that can be put into a mirror are limited because a size of rearview mirrors is limited. Specifically, the area of a mirror&#39;s reflective surface must be large enough horizontally and vertically so that a driver can see enough to recognize what is behind him or her. At the same time, the total vertical dimension of a mirror must be short enough so that the driver can see under the mirror out the vehicle&#39;s front window. The resulting area on a face of the mirror under the reflective surface area (sometimes called a “chin” herein) is relatively small in a vertical direction. 
     A problem occurs because “framed” buttons positioned in the “chin” area are forced to be “too small” from an ergonomic point of view. “Framed” buttons, as used herein, are buttons that are surrounded on four sides by a fixed marginal material so that the button is fully contained or bordered. Four-sided framing of buttons is desirable because the button is captured in a manner so that its movement is restricted to a perpendicular “button-depressing” direction only. Captured or “framed” buttons also have a reduced tendency to rattle. A problem is that, when buttons are ergonomically “too small”, vehicle drivers tend to miss-hit them (i.e. press the wrong button), or the vehicle drivers simply cannot find or actuate the correct button. Miss-hit buttons can be a particularly frustrating problem at nighttime or in darkness since drivers have difficulty seeing and identifying symbols and letters on the small buttons. Also, there is often not enough room on the mirror face adjacent the button to place adequately-sized, recognizable identification symbols or identifying letters. For example, one known mirror was specified to have a vertical height of at least two inches in a critical central area of its reflective viewing area. Simultaneously, the “chin” area on that mirror was specified to be about 21.5 mm. The button, which was framed on all four of its sides, had a height limited to 8 mm, which is only about 37% of the available space on the “chin” area. One reason was because of the structural requirements of the four sides that define the button opening. Specifically, there must be sufficient width and structure in the “framing” material on all four sides of the button opening to prevent breakage and warranty. The breakage and warranty could be caused by several different factors, such as by excessive force received from a vehicle driver mis-hitting the button frame while attempting to depress a button on the mirror. A solution is desired that will permit buttons to be enlarged for more easy selection and actuation, while still meeting the decor, function, strength, and inherent small size requirements of interior rearview mirrors. 
     Another problem occurs as multiple functions and features are added to interior rearview mirrors. Multiple functions and features result in multiple push-buttons on the mirror for turning “on” and “off” the different functions and features. It is preferable for drivers to be able to select a particular button from a plurality of buttons without having to look away from his/her driving and at the mirror for any length of time. Even more preferable, it is desirable that the driver doesn&#39;t have to look at the mirror at all in order to select a desired push-button. This is important since such a distraction can adversely affect safe driving. 
     Yet another problem can occur when a driver grasps a mirror to adjust an angle of the mirror, since the driver can accidentally depress and actuate buttons. This is another reason why four-sided framing of button are traditionally desired, because, in theory, there is less likelihood of accidentally depressing a button when the button is shielded on all four of its sides. 
     Accordingly, an apparatus is desired solving the aforementioned problems and having the aforementioned advantages. 
     In one aspect of the present invention, a rearview mirror includes a housing adapted to support a rearview mirror subassembly, and a bezel attached to and partially covering a front of the housing. The bezel includes a section of material defining a three-sided button opening having an open side on a face of the bezel. A button is positioned in the three-sided button opening and is operably supported therein for movement between a switch-actuating position and a non-actuating position. 
     In another aspect of the present invention, a rearview mirror includes a housing adapted to support a rearview mirror subassembly, and a bezel attached to and partially covering a front of the housing, where the bezel includes a section of material defining a button opening on a face of the bezel. One of the housing and the bezel include an exterior surface that extends away from the face, and the button opening extends from the face around onto the exterior surface. A button is positioned in the button opening and is operably supported by one of the housing and the bezel for movement between a switch-actuating position and a non-actuating position. The button includes a front first surface that is generally flush with the face of the bezel when the button is in the actuating position and further includes a second surface that is generally flush with the exterior surface of the bezel when the button is in the non-actuating position. 
     In another aspect of the present invention, a rearview mirror includes a housing adapted to support a rearview mirror subassembly, and a bezel attached to and partially covering a front of the housing, where the bezel includes a section of material defining a button opening on the bezel. A button is positioned in the button opening and is operably supported therein for movement between a switch-actuating position and a non-actuating position. A feel-and-locate feature is formed on one of the housing, the bezel and the button. The feel-and-locate feature is aligned with the button and configured and adapted so that a vehicle operator can identify a location of the button by feel without the vehicle operator having to look at the button. 
     In another aspect of the present invention, a bezel is provided that is adapted to attach to and cover a front edge of a mirror housing for a rearview mirror, where the mirror housing is adapted to support a rearview mirror subassembly. The bezel includes a ring-shaped body with top, bottom, and sidewall sections forming a loop. At least one of the wall sections includes a face and an exterior surface that extends away from the face. The face includes marginal material defining a button opening that extends from the face onto the exterior surface. A button is positioned in the button opening and is operably supported for limited movement by the marginal material of the bezel between a switch-actuating position and a non-actuating position. 
     In another aspect of the present invention, a rearview mirror includes a housing adapted to support a rearview mirror subassembly, and a loop-shaped bezel attached to and partially covering a front of the housing, where the bezel includes a section of material defining a button opening on a face of the bezel. A button is snap attached into the button opening and is operably pivotally supported for limited movement by one of the housing and the bezel for movement between a switch-actuating position and a non-actuating position 
     In another aspect of the present invention, a rearview mirror adapted for use in passenger vehicles includes a housing and a rearview mirror subassembly supported in the housing. The rearview mirror subassembly includes a reflector adapted to reflect images to a vehicle driver so that the vehicle driver can see toward a rear of the vehicle without turning his/her head. The reflector provides a reflective viewing area with a bottom edge. A bezel is attached to and partially covers a front of the housing and of the mirror subassembly. The bezel includes a “chin” section of material below the bottom edge of the reflective viewing area that defines a button opening on a face of the bezel, with a vertical dimension of the button opening being at least 75% of a predetermined vertical dimension of the “chin” area. 
     In yet another aspect of the present invention, a rearview mirror includes a housing supporting a rearview mirror subassembly, and a bezel attached to and partially covering a front of the housing and of the rearview mirror subassembly. One of the housing and the bezel defines a plurality of button openings on a face of an assembly of the housing and the bezel. A plurality of buttons are positioned in the button openings and are operably supported therein for movement between a switch-actuating position and a non-actuating position. The housing further includes a difficult-to-see lower rear surface defining an elongated finger rail that is spaced from and extends parallel a line defined by the plurality of buttons. The finger rail provides a feature along which a vehicle driver can slide his/her fingers when the vehicle driver is searching by feel for a particular one of the buttons. 
     One object of the present invention is to provide a mirror with buttons, where the buttons are surprisingly and unexpectedly large and accessible, despite a relatively small area under the reflective viewing area on a face of the mirror. 
     Another object is to provide a mirror with buttons, where a finger rail and locator features on the mirror and/or the buttons allows a vehicle driver to select and operate buttons without having to look at and visually identify a particular button. 
     Another object is to provide a mirror with buttons, where the buttons have accessible surfaces on the face and bottom of the mirror, but where the buttons are pivoted to the mirror in a manner that reduces or eliminates the likelihood of the buttons being accidentally actuated when the driver grasps the mirror for adjusting an angle of the mirror. 
     These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front view of a rearview mirror embodying the present invention; 
     FIGS. 2,  3 , and  4  are cross-sections taken along the lines II—II, III—III, IV—IV in FIG. 1; and 
     FIG. 5 enlargement of the circled area V in FIG.  4 ; 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     An electrified rearview mirror  20  (FIG. 1) includes a housing  21  (FIG. 3) supporting a rearview mirror subassembly  22 , such as the illustrated electrochromic (EC) mirror having multiple electronic functions therein. A bezel  23  is attached to and covers a front edge of the housing  21  and also covers a perimeter portion of the mirror subassembly  22 . The bezel  23  includes a bottom wall section  24  (FIG. 1) defining a plurality of three-sided button openings  25  on a face of the bezel  23 , with the openings  25  extending onto a rearwardly extending bottom flange  26  of the bottom wall section  24 . Push-buttons  27  are pivotally supported in the opening  25 , with the hinge axis of each push-button  27  being at a low and rearwardly-spaced position on the respective buttons  27 . This helps prevent the buttons  27  from being accidentally depressed, such as may happen when the mirror housing  21  is grasped by a vehicle driver tying to adjust an angle of the mirror  20 . Specifically, the pivot is located at a bottom point where the driver&#39;s bottom finger pressure will bear directly against the pivot axis, and thus the button will not be accidentally depressed or pivoted as the mirror is adjusted. 
     A shape of the buttons  27  and the openings  25  is significant in the present mirror  20 . Specifically, the shape of the buttons  27 , including their lower portion, which wraps under the mirror, permits the buttons  27  to be made surprisingly and substantially larger in size than similar mirror constructions where the button is framed on four sides on a face of a mirror. For example, the illustrated buttons  27  can be made up to 12.5 mm tall (or taller) in vertical height D 2  (FIG. 1) on a face of a mirror having a dimension D 3  of about 75 mm, even where the “chin” section is specified to have a vertical dimension D 4  of about 20 mm, where the “button” panel area of the “chin” section has a vertical dimension D 5  of about 15 mm, and where the specified reflective portion D 1  is at least about 51 mm at its center point. (i.e. D 2 /D 4 &gt;50%, or more preferably D 2 /D 4 =62.5%, D 2 /D 5 &gt;50%, or more preferably D 2 /D 5 &gt;80%, and D 2 /D 3 &gt;15% and more preferably D 2 /D 3 &gt;16% in front view). This would not be possible in most mirrors due to a limitation on the chin section (D 5 ) and the total assembly height dimension (D 3 ). Further, the three-sided button opening  25  has an open bottom side on the face that permits much easier access than with traditional four-sided framed buttons, due to its open bottom side. Still further, when the exposed bottom surface of the button  27  is combined with the button&#39;s front face, the new button construction provides an enlarged target with two directions of access. The phrase “two directions of access” is intended to refer to access to a face of the buttons  27  from a front and a bottom direction, as permitted by the three-sided opening, keeping in mind that the button axis, which is below and slightly rearward of a face of the buttons  27 , limits “vertical” actuation of the buttons  27 . Notably, the “low” and “rearward” location of the button pivot axis prevents the open bottom side from causing problems from accidental depression, as discussed below. 
     It is noted that traditional button constructions on mirrors are framed on all four sides in order to better “capture” the buttons to prevent rattling and to provide for smooth operation. The material forming the “frame” must be sufficient to maintain its shape, and to withstand forces that occur when in use. Most “frame” sections are about 2.0 mm thick. This forces the area around a button to take up area that would otherwise be used by the button itself. In the present example, the button  27  is made at least 2 mm larger by elimination of the framing section at a bottom of the button opening  25 . Still further, in the present example, the button  27  is made even larger due to total elimination of the bottom wall on a face of the bezel  23 . 
     To summarize, the “three-sided button opening” design results in larger buttons  27  that are better able to meet ergonomic and identification demands of modern consumers, while still permitting the total mirror size and chin area to remain within limited manufacturing size specifications. The present button arrangement further permits snap-assembly to the bezel, thus saving assembly costs, as discussed below. 
     Interior rearview mirrors, including electrochromic mirror constructions and mirror constructions with internal electrical circuits and components are generally known in the art, and the details of the same do not need to be described extensively herein for a person of ordinary skill to understand the present invention. It is sufficient to note that the present mirror subassembly  22  includes front and rear glass elements  30  and  31  (FIG.  3 ), an electrochromic (EC) material  32 , a reflector layer  33  (on either a front or rear surface of the rear glass element  31 ), and electrical conductors  34  and  35 . A printed circuit (PC) board  36  is located in the housing  21 , and includes a circuit thereon for causing an electrical potential across the EC material  32  to darken reflected images, such as when bright glaring headlights are sensed at night. The printed circuit board  36  potentially further includes multiple circuits, such as for supporting functions such as compass/direction sensing, global position sensing, temperature sensing, daylight sensing, sensing of glaring light such as bright headlamps, keyless entry, passenger airbag on/off control, garage door control function and transmitting, telecommunication functions, and the like. These additional functions may be supported by circuits that are partially or completely on the PC board  36  or in the housing  21 . The present inventive button construction concerns buttons operably mounted on the mirror  20  that are adapted to provide on/off control and selection of these various circuits and functions. 
     Bezel  23  is loop-shaped, and includes top and side wall sections  37 - 39  (FIG. 1) that combine with bottom wall section  24  to cover a perimeter of the mirror subassembly  22  and to cover the front edge of the housing  21 . Each of the wall sections  37 - 39  and  24  include an aesthetic perimeter face flange  44  (FIG. 3) that extends around a perimeter of the mirror subassembly  22 , and a resilient sealing flange  45  that engages a front surface of the front glass element  30 . Each of the wall sections  37 - 39  and  24  further include a rearwardly extending bottom flange  42  (see FIG. 3) that overlappingly engages a front edge  43  of the housing  21 . The overlapping portions preferably include mating resilient hook and aperture connectors (not specifically shown) for providing snap attachment of the bezel  23  to the housing  21 , although it is noted that other connecting mechanisms can also be used. 
     In the bottom wall section  24 , there is an extended face flange  46  (FIG. 1) that extends downwardly from the aesthetic perimeter face flange  44 . Also, the bottom flange  42  is extended rearwardly a significant distance. The illustrated bezel  23  includes marginal material forming five button openings  25 , each of which include a face portion in the extended face flange  46  and a bottom portion in the rearwardly extending bottom flange  42  of the bottom wall section  24 . It should be apparent that more or less button openings can be formed. The illustrated button openings  25  are three-sided on the face of the bezel  23 , and include a downwardly open bottom edge. Thus, the button openings  25  permit access to the buttons  27  both from the face and also from a bottom of the bezel  23 . 
     The button-to-bezel connection is believed to be particularly novel in the present mirror arrangement. The rearwardly extending bottom flange  42  of bezel  23  includes a pair of spaced-apart hinge tabs  48  (FIG. 5) that extend upwardly into the button opening  25 . The hinge tabs  48  define a hinge axis  48 ′ located at a bottom of the buttons  27  at a location rearward of a face of the bezel  23 . This reduces the likelihood of a person accidentally depressing a button  27  when adjusting the mirror  20 . A rearwardly extending intermediate flange  48 ″ extends rearwardly from a lower edge of the bottom face flange  44 , and a stop flange  49  extends downwardly from the intermediate flange  48 ″ into the button opening  25 . Button  27  includes a front wall  50  having a face that, when the button  27  is in a switch non-actuating position, extends generally flush with the front surface of the bezel  23 , and further includes a bottom wall  51  with a bottom exterior surface that, when the button  27  is in a non-actuating position, extends generally flush with the bottom flange  42  of the bezel  23 . The term “generally flush” is intended to mean that the button surface can be proud (i.e. raised) or recessed from the bezel surfaces, such as one or a few millimeters raised or recessed, and still be within a scope of the present invention. 
     The bottom wall  51  includes a pair of horizontal slots  51 ′ that matably engage the hinge tabs  48  to pivotally mount the button  27  to the bezel  23  in the opening  25 . The button  27  further includes a top wall  52  that extends parallel the intermediate flange  48 ″. A hook  53  on the top wall  52  engages the stop flange  49  to limit outward movement of the button  27  in the opening  25 . A lip  54  on the front wall  50  engages the stop flange  49  to limit depression of the button  27 . Advantageously, the button  27  can be snapped into position by engaging the tabs  48  into the slots  51 ′, and then pressing a top of the button  27  so that the hook  53  snaps past the stop flange  49 . Vertical side flanges  55  (FIG. 2) are provided on the bottom wall section  24  to slidingly engage sides of the button  27  to further stabilize the button  27  in the opening  25 . The vertical side flanges  55  also stabilize the bottom wall section  24  of the bezel  23  to create a more robust and sturdy part, both before and after assembly of the bezel  23  onto the housing  21 . As illustrated, the side flanges  55  include lateral flanges  56  that engage sidewalls  57  and  58  on the buttons  27  to further assist in providing a positive stop when depressing the button  27 . 
     A switch  60  (FIG. 3) is provided on the PC board  36 . The intermediate flange  48 ″ abuts the PC board  36  at location  60 ′ for optimal location of a depth of the PC board  36  relative to the bezel  23 . The switch  60  includes a base portion  61  on the PC board, a conductor portion  62  raised above the PC board, and a resilient wall portion  63  that resiliently interconnects the base and conductor portions  61  and  62 . Contacts are located below the conductor portion  62  on base portion  61 . The conductor portion  62  engages and is attached to an end of the button wall  52 , and the resilient wall portion  63  biases the conductor portion  62  and in turn, biases the button  27  to an outward non-actuating position. When a person depresses the button  27 , the resilient wall portion  63  flexes and rolls, such that the conductor portion  62  comes into contact with the contacts on base portion  61 , thus completing the circuit of the switch  60 . It is noted that many different switches are known in the art and can be used without departing from the present inventive concepts. For example, a tactile switch can be used instead of the “carbon pill” type switch  60  shown in FIG.  3 . 
     The housing  21  (FIG. 3) includes an exterior surface formed by a bottom wall  66  and a back wall  67 . A channel  68  (called a “finger rail” herein) is formed across a lower part of the back wall  67  near the bottom wall  66  at a location where a person&#39;s thumb or fmgers naturally come to rest when the person is grasping and adjusting the mirror  20 . The finger rail  68  forms a finger rail or groove along which a person can slide his/her fingers when trying to select and depress/operate a button  27 . Notably, it is contemplated that the finger rail  68  could also be a raised ridge or any other elongated directional feature that can be felt. Protrusions  69  are formed in the finger rail  68  at locations aligned with the buttons  27 . Thus, a person can, without looking at the mirror, start at one end of the mirror  20  and slide his/her fingers along the finger rail  68 , counting the protrusions until they reach the button  27  for the electrical option that they want to select. It is contemplated that the protrusions can instead be depressions, surface roughness, or other features that let the driver know which button  27  that his/her fingers are at. Also, the protrusions can be Braille or symbolically shaped to communicate information to the driver by feel. Also, it is contemplated that the protrusions can be located on the buttons themselves, or on the bezel, if desired. 
     In the foregoing description, those skilled in the art will readily appreciate that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.